Method and apparatus for forming parts from a continuous stock material and associated forge

ABSTRACT

The present invention provides a method and apparatus for forming a plurality of parts, such as spade-type boring bits, from a continuous stock material. Thus, the various steps of the forming method of the present invention can be performed to predetermined portions of the continuous stock material prior to separating the continuous stock material into discrete parts, thereby enhancing the efficiency of the forming process. The present invention also provides an improved forge for forming portions of the continuous stock material into parts having a predetermined shape. The forge can be designed to provide a clearance region proximate the forward end of the ram to permit slight flexing of the forward end of the ram in a radially outward direction during forging operations. The forge can also include a lubrication system for lubricating its various components. In addition, the forge can incrementally rotate the ram after one or more parts have been forged. By repeating the incremental rotation of the ram, the forge will eventually rotate the ram a full 360°. An improved forging die is also provided which includes a back surface having a conical medial section and a pair of conical lateral sections that are recessed relative to the medial section such that forces will principally be applied to the medial section during forging operations.

RELATED APPLICATIONS

This application is divisional of U.S. patent application Ser. No.09/215,159 filed Dec. 18, 1998, now U.S. Pat. No. 6,290,437 which is acontinuation-in-part of U.S. patent application Ser. No. 09/143,630,filed Aug. 28, 1998, now abandoned, which is a continuation of U.S.patent application Ser. No. 08/662,665, filed Jun. 14, 1996 and nowissued as U.S. Pat. No. 5,842,267 which is a continuation-in-part ofU.S. patent application Ser. No. 08/366,986, filed Dec. 30, 1994 and nowissued as U.S. Pat. No. 5,700,113 and U.S. patent application Ser. No.08/514,071, filed Aug. 11, 1995 and now issued as U.S. Pat. No.5,697,738, the contents of each being expressly incorporated in theirentirety herein.

FIELD OF THE INVENTION

The present invention relates generally to methods and apparatus forforming parts of a predetermined shape, such as drill bits and, moreparticularly, spade-type boring bits, from a continuous stock material.The present invention also relates generally to improved forges forforming parts of a predetermined shape, such as drill bits and, moreparticularly, spade-type boring bits.

BACKGROUND OF THE INVENTION

Each day, a myriad of metal and plastic parts of a variety ofpredetermined shapes are manufactured, such as by a forging process inwhich a permanent change in the shape of the part occurs. These partsare oftentimes manufactured in large quantities and are used in manydifferent applications. For example, a number of tools, such as drillbits, screwdriver bits, router bits, percussion bits and jigsaw andreciprocating saw blades, are produced in mass quantities every day.Likewise, a number of other parts, such as fasteners, impact wrenchanvils, coil and ballpoint chisels, gears, shafts, equalizer beams andactuator rods, are also manufactured in large quantities every day.

Accordingly, a number of manufacturing processes have been developed toform parts of a predetermined shape in large numbers. Thesemanufacturing processes generally include a number of independentoperations or steps which are performed in a predetermined sequence inorder to create parts of the desired shape. For example, typicalprocesses for manufacturing metal parts generally include forgingoperations, trimming operations, heat-treating operations and grindingand other finishing operations.

These manufacturing processes are typically designed to form a number ofdiscrete workpieces into respective parts of a predetermined shape.Thus, these conventional manufacturing processes generally include aninitial step of providing a number of discrete workpieces of the desiredsize and length. For example, a metal wire or rod can be cut into anumber of discrete pieces prior to beginning the actual manufacturingprocess. Thereafter, the plurality of discrete workpieces areindividually processed in order to create a plurality of parts of thepredetermined shape.

As a result, each discrete part must generally be collected followingevery operation of these conventional manufacturing processes such thatthe part can be transported to the next stage or operation of themanufacturing process. In addition, since the parts must generally bealigned in a predetermined manner during each operation of thesemanufacturing processes, each part must generally be individuallyoriented prior to each next stage of the manufacturing process. Thus,even though parts are generally collected and transported between stagesof these manufacturing processes in batches, these conventionalmanufacturing processes still generally require extensive handling ofthe parts in order to collect, transport and properly orient the partsbetween each stage of these manufacturing processes. These conventionalmanufacturing processes also typically require a relatively large numberof parts to be in process at all times due to the batch-type processing.As will be apparent, the time and labor required to collect, transportand properly orient parts during these conventional manufacturingprocesses decreases the efficiency with which these parts are fabricatedand, correspondingly, increases the cost of the resulting parts.

The inefficiencies created by handling and processing a plurality ofdiscrete parts and the increased costs of maintaining a relatively largenumber of partially formed parts in process are particularly significantfor those manufacturing processes which are designed to produce a largenumber of parts each day, such as tens of thousands, if not hundreds ofthousands, of parts each day. For example, conventional manufacturingprocesses which produce metallic parts, such as drill bits, router bits,fasteners, percussion bits, jig saw and reciprocating saw blades, impactwrench anvils, coil and ballpoint chisels, gears, shafts, screwdriverbits, equalizer beams and actuator rods, generally produce parts atrates up to thousands or more per day.

In order to demonstrate the inherent inefficiencies of theseconventional manufacturing processes which individually process a largenumber of discrete parts, the manufacturing process employed to formspade-type boring bits (hereinafter referred to as “spade-bits”) isdescribed hereinafter. Spade bits are typically formed by a hot forgingprocess. According to this process, a coil of wire stock of a givendiameter is cut into pieces, each of which is approximately the lengthof an individual spade bit. Each piece is then headed to form a portionof material with an increased diameter at the first end of the segment,i.e., a bulb of material having an increased diameter over a shorterlength at the first end. Either during this initial heated process orfollowing further heating of the bulb of material, the part is forged bycompressing the heated bulb of material between a pair of opposed dies.Typically, the pair of opposed dies are closed in a rectilinear mannersuch that the heated bulb of material is subjected to compressive forceswhich displace the material into the predetermined fixed boundary shapedefined by the dies. The forged part can then be trimmed and finished toproduce spade bits such as those described above. An identification markcan also be stamped on the spade bit during its processing.

By initially cutting the wire stock and/or billets into a number ofdiscrete pieces, however, the parts must be individually handled andprocessed throughout the hot forging process, thereby decreasing theefficiency with which the spade its are fabricated and, correspondingly,increasing the resulting costs of the spade bits. For example, eachindividual part must be collected following each stage of thefabrication process and transported to the next stage. In addition, eachindividual part must be appropriately aligned during each step of theprocess to ensure that the input shape of the part serves as a properand admissible preform to satisfy the requirement of each subsequent dieoperation, including die fill, such that the resulting spade bits meetthe desired product tolerances.

SUMMARY OF THE INVENTION

A method and apparatus is therefore provided according to the presentinvention for forming a plurality of parts, such as spade bits, from acontinuous stock material. Thus, the various steps of the forming methodof the present invention can be performed to predetermined portions ofthe continuous stock material, prior to separating the continuous stockmaterial into a number of discrete parts. The efficiency of the formingprocess is thereby enhanced since individual parts need not betransported and oriented numerous times during the forming operations.By not requiring that the individual parts be handled during the formingoperations, the quality and tolerance control of the parts formed by theforming method and apparatus of the present invention will also beenhanced since such handling of individual parts generally increases theopportunities for misalignment and contributes to poor tolerance controlduring the manufacturing process. In addition, the forming method andapparatus of the present invention effectively reduces the number ofparts in process at any one time during the manufacturing process bylimiting the number of batch operations required in comparison toconventional fabrication processes.

According to the forming method and apparatus of the present invention,a plurality of indexers are synchronized to incrementally advance thecontinuous stock material along a predetermined path such that the stockmaterial advances longitudinally in a downstream direction. Followingeach intermittent advance of the continuous stock material, a portion ofthe continuous stock material is formed, such as with a forge, into afirst predetermined shape.

According to this embodiment of the present invention, the plurality ofindexers include an upstream indexer for intermittently pushing thecontinuous stock material in the downstream direction from a locationspaced in an upstream direction from the forge. Additionally, theplurality of indexers include a downstream indexer for intermittentlypulling the continuous stock material in a downstream direction from alocation spaced in the downstream direction from the forge. Bysynchronizing the intermittent pushing and pulling, the continuous stockmaterial is advanced longitudinally in the downstream direction alongthe predetermined path. By synchronously pushing and pulling thecontinuous stock materials from locations that are upstream anddownstream of the forge, respectively, the forming method and apparatusof the present invention advances the continuous stock material moresmoothly in the downstream direction and significantly reduces thepossibility that the continuous stock material will kink or bendrelative to conventional forming processes which utilize a singleupstream indexer.

Preferably, the upstream indexer intermittently pushes continuous stockmaterial by a predetermined distance in the downstream direction and thedownstream indexer intermittently pulls the continuous stock material bythe same predetermined distance in the downstream direction. As such,the continuous stock material can be intermittently advanced by thepredetermined distance each time that the continuous stock material ispushed and pulled by the respective indexers. Additionally, the upstreamand downstream indexers are preferably synchronized such that theupstream and downstream indexers concurrently pull and push thecontinuous stock material in a downstream direction, respectively.

The forming method and apparatus generally includes a clamp for securelygripping and holding a fixed portion of the continuous stock materialwhile another portion of the continuous stock material is formed intothe first predetermined shape. According to the present invention, theclamp and, more particularly, the fixed portion of the continuous stockmaterial held by the clamp is disposed in a predetermined longitudinaldirection relative to the formed portion of the continuous stockmaterial which is shaped into the first predetermined shape.

As a result of processing a continuous stock material, the continuousstock material grows in both longitudinal directions during the formingoperations. According to the present invention, however, thelongitudinal growth of the continuous stock material created during theforming operation is at least partially compensated for by allowingmovement of the continuous stock material in a longitudinal directionopposite the predetermined longitudinal direction established by therelative positions of the fixed portion of the continuous stock materialand the formed portion of the continuous stock material. By compensatingfor the longitudinal growth of the continuous stock material, theforming method and apparatus of the present invention can form thecontinuous stock material into a plurality of parts prior to separatingthe stock material into the plurality of discrete parts, therebyincreasing the manufacturing efficiency of the parts.

The forming apparatus of the present invention also preferably includesa longitudinal growth monitor for monitoring the longitudinal growth ofthe continuous stock material during forming operations. The formingapparatus also advantageously includes a controller, responsive to thelongitudinal growth monitor, for terminating forming operations once thelongitudinal growth of the continuous stock material is at least asgreat as a predetermined growth threshold.

Accordingly, the forming method and apparatus of the present inventioncan readily manufacture parts of a predetermined shape and size in aprecisely controlled fashion.

According to one embodiment, the forge includes a die assembly includinga plurality of dies disposed about the continuous stock material andmeans for at least partially closing the plurality of dies about thestock material. Once closed, the plurality of dies define a cavity of apredetermined shape which, in turn, defines the shape of at least aportion of the resulting part. According to the present invention, theplurality of at least partially closed dies also define entry and exitports through which the continuous stock material extends.

The means for at least partially closing the plurality of dies about thecontinuous stock material preferably includes a ram having a die housingwhich defines a die cavity opening through the forward end of the ramand adapted to receive and circumferentially encompass the plurality ofdies, thereby structurally reinforcing the forging dies during theforging process. Thus, by at least partially inserting the plurality ofdies within the die cavity defined by the ram, the plurality of dies canbe at least partially closed about the continuous stock material.

The forge also generally includes a head which defines a passagewayextending lengthwise through at least a portion of the head and defininga lengthwise extending axis. As such, the ram can be alternatelyadvanced and retracted within the passageway defined by the head duringforging operations. During the lengthwise advancement of the ram, thedie assembly will be further inserted into the die cavity and theforging dies will be correspondingly forced radially inward in order toforge the part of the predetermined shape. Similarly, during theretraction of the ram following completion of the forging operations,the die assembly will be at least partially removed or withdrawn fromthe die cavity such that the forging dies can move radially outwardlyaway from the continuous stock material.

The forge of the present invention also preferably includes a carriageon which the head, the ram and the plurality of dies are mounted. Thecarriage is mounted to move in a longitudinal direction relative to thecontinuous stock material. As a result, the carriage can move in alongitudinal direction opposite the predetermined longitudinal directionestablished by the relative positions of the fixed portion of thecontinuous stock material and the formed portion of the continuous stockmaterial in order to further compensate for the longitudinal growth ofthe continuous stock material created during the forming operations. Inparticular, the carriage is adapted to move to compensate for thelongitudinal growth of that portion of the continuous stock materialbetween the formed portion of the continuous stock material and thefixed portion of the continuous stock material. As a result of thislongitudinal movement of the carriage, the plurality of dies remain atleast partially closed about the same portion of the stock materialduring the entire forming step.

According to one advantageous embodiment, the forge also includesbiasing means for longitudinally biasing the carriage with apredetermined longitudinal bias force so as to retard the longitudinalmovement of the carriage. According to one aspect of the presentinvention, the longitudinal bias force applied by the biasing means canbe altered according to a predetermined schedule. For example, thebiasing means can increase the longitudinal bias force over time toencourage lateral expansion of the workpiece within the cavity definedby the plurality of dies such that the entire cavity is filled.

While the clamp continues to hold the fixed portion of the continuousstock material, the forming method and apparatus of the presentinvention can form another portion of the continuous stock material intoa second predetermined shape, such as with a second forge. Once bothportions of the continuous stock material have been formed, the clampcan release the fixed portion of the continuous stock material such thatthe continuous stock material can be further advanced along thepredetermined path. Thereafter, the steps of the forming method can berepeated such that parts which have both the first and secondpredetermined shapes can be fabricated in mass.

According to one advantageous embodiment of the present invention, thecontinuous stock material includes a number of longitudinally spacedapart registration features. For example, the continuous stock materialcan include a registration feature defined between those portions of thecontinuous stock material which will be formed into respective ones ofthe plurality of parts by the forming method and apparatus of thepresent invention.

Accordingly, the forming apparatus of one advantageous embodiment of thepresent invention can include a sensor for identifying a registrationfeature on the continuous stock material. According to this embodiment,the forge can therefore include a positioner for positioning the forgesuch that the portion of continuous stock material which is formed islongitudinally spaced from the registration feature identified by thesensor by a predetermined distance. Likewise, the clamp of the formingapparatus of this embodiment of the present invention can also include apositioner for positioning the clamp such that the clamp securely gripsa fixed portion of the continuous stock material which is longitudinallyspaced from the registration feature by a predetermined distance.

The forming method and apparatus of one embodiment of the presentinvention can also include trimming means, such as a trimmer, disposeddownstream of the forge for trimming predetermined portions of eachpart. The trimmer can also include a positioner for positioning thetrimmer such that the predetermined portions which are trimmed arespaced from the registration feature by a predetermined distance.Likewise, the forming apparatus of one embodiment can include a cutter,disposed downstream of the first and second forges, for cutting thecontinuous stock material following formation of the parts so as tothereby separate the continuous stock material into a plurality ofdiscrete parts. As described above in conjunction with the forge, clampand trimmer, the cutter can include a positioner for positioning thecutter such that the portion of the continuous stock material which iscut is longitudinally spaced from the registration feature by apredetermined distance. By identifying the registration features definedby the continuous stock material, the various operations of the formingmethod and apparatus of the present invention can be performed in aprecise manner on predetermined portions of the continuous stockmaterial.

According to one advantageous embodiment of the present invention, anapparatus is provided for trimming and separating the plurality of partsformed from a continuous stock material which includes a plurality oflongitudinally spaced apart registration features. The apparatus of thisembodiment includes a trimmer for trimming predetermined portions ofeach part and a separator such as a snipper, a saw or other cutter,disposed downstream of the trimmer for separating each part from thecontinuous stock material once predetermined portions of the part havebeen trimmed. Advantageously, the separator is operably connected to thetrimmer such that the separator and the trimmer are moved together inthe longitudinal direction. However, the apparatus of this embodimentpreferably includes a positioner for positioning the separator relativeto the trimmer such that the trimmer and separator can be appropriatelyspaced, such as to process parts of different lengths. In order toproperly position the trimmer and the separator, the apparatus of thisembodiment also includes a sensor for identifying a registration featureon the continuous stock material and a positioner, responsive to thesensor, for jointly positioning the trimmer and the separator such thatthe portion which is trimmed and the position at which a part isseparated from the remainder of the continuous stock material arelongitudinally spaced from the registration feature by a predetermineddistance. By moving the trimmer and the separator as a unit, theapparatus of this embodiment of the present invention simplifies theoverall design of the forming method and apparatus by reducing thenumber of components which must be individually positioned relative tothe registration features of the continuous stock material.

In addition to positioning the trimmer and the separator relative to theregistration features of the continuous stock material, the positioneralso permits the trimming and separating station to serve as an indexer.In this regard, the trimmer securely holds the continuous stock materialwhile predetermined portions are trimmed. While the trimmer is securelyholding the continuous stock material, the positioner can thereforeadvance the trimmer and the separator in the downstream direction inorder to effectively pull the continuous stock material along thepredetermined path. Correspondingly, the forming apparatus can includean indexer which also intermittently advances the continuous stockmaterial in the downstream direction, such as by pushing the continuousstock material along the predetermined path, as described above. Bysynchronizing the indexer and the positioner of the trimming andseparating station, the continuous stock material can be concurrentlyadvanced in the downstream longitudinal direction by both the indexerand the positioner.

According to one advantageous embodiment of the present invention, atleast one forging die includes a contact surface which defines a portionof the cavity for contacting and shaping the workpiece into thepredetermined shape of the resulting part. More often, the plurality offorging dies include at least two forging dies, such as upper and lowerforging dies, which include respective contact surfaces to deform andshape the workpiece upon actuation or closing of the forging dies.According to this embodiment of the present invention, the plurality offorging dies are moved inwardly in a predetermined direction as theforging dies are inserted within the die cavity defined by the ram,thereby at least partially closing the forging dies about the continuousstock material. The predetermined inward direction in which the forgingdies move is preferably oblique to the respective contact planes of theforging dies. For example, the contact plane of at least one forging dieand a reference plane perpendicular to the predetermined direction ofmovement of the forging die define an angle of between about 10° andabout 20° therebetween, according to one advantageous embodiment. Therespective contact surfaces therefore impart both axial and radialforces to at least portions of the workpiece to form the part ofpredetermined shape within the cavity defined between the plurality offorging dies. Due to the shape of the contact surfaces and the resultingorientation of the axial and radial forces applied, compressive, tensileand shear forces are generated within the workpiece which facilitate theefficient formation of the part of predetermined shape. Accordingly,thin parts which have a relatively large diameter can be readily forgedaccording to this aspect of the present invention. Further, the powerrequired to forge parts of a predetermined size and shape is reduced incomparison to conventional compressive forging processes by impartingcompressive, tensile and shear forces at desirable locations within theworkpiece.

In addition to the inner contact surface, each forging die preferablyincludes an opposed back surface having a predetermined shape foroperably contacting those portions of the ram which define the diecavity. According to one embodiment of the present invention, the backsurface of the forging dies have been advantageously designed to includea medial section having a partial conical shape. In addition, the backsurface includes first and second lateral sections disposed on oppositesides of the medial section. Each lateral section preferably also has apartial conical shape. However, the radius defined by the conical medialsection is larger than the radius defined by the conical lateralsections at each corresponding location along the length of the forgingdie. As such, the back surface of the forging die of this advantageousembodiment no longer presents a continuously smooth surface across theentire back surface. In addition, the first and second lateral sectionsare recessed relative to the medial section.

Since the forging die is typically tapered such that the contact surfaceis separated from the back surface by a greater amount at a first end ofthe forging die than at a second end of the forging die, the medialsection of the back surface of this advantageous embodiment is alsopreferably tapered so as to be wider proximate the first end of theforging die and narrower proximate the second end of the forging die. Asa result, the medial section has a trapezoidally shaped surface. As aresult of the unique construction of the back surface of the forgingdie, the forging die advantageously contacts those portions of the ramwhich define the die cavity in a relatively even manner across most, ifnot all, of the conical medial section of the forging die as opposed toconventional forging dies which contacted the ram in a much smallerarea, thereby significantly increasing the forces applied to at leastportions of the forging die and correspondingly increasing the wear ofthe die and decreasing the effective lifetime of the die.

According to one aspect of the present invention, an improved forge isprovided. According to one embodiment, the interior surface of the headand the exterior surface of the ram cooperate to define a clearanceregion proximate the forward end of the ram which permits a slightdeflection of the forward portion of the ram in a radially outwarddirection as the ram is advanced over the die assembly. In particular,the clearance region defines a larger gap between the head and theforward portion of the ram than exists between the head and otherportions of the ram, thereby reducing, if not eliminating, interferencebetween the forward portion of the ram and the head. However, a portionof the ram is preferably maintained in an interference fit with the headso as to guide the ram during its lengthwise advancement and retraction.For example, the head can include a bronze bushing for engaging the ramand for providing the interference fit therewith.

In one embodiment, the head defines a circumferentially extended grooveopening into the passageway at a location proximate the forward end ofthe ram. In this embodiment, the groove defines the clearance region topermit slight radially outward deflection of the forward end of the ramduring forging operations. Preferably, the circumferential grooveextends from a first location at least as forward as the forward end ofthe ram following the lengthwise advancement of the ram to a secondlocation at least as rearward as a location corresponding to theposition to which the plurality of forging dies are inserted into thedie cavity defined by the ram following the lengthwise advancement ofthe ram.

The forge of another embodiment includes a rotator for imparting anincremental relative rotation between the ram and the die assembly afterat least one part has been forged. Typically, the rotator incrementallyrotates the ram about the lengthwise extending axis after at least onepart has been forged. In this regard, the ram is preferably rotatedwhile the ram is retracted and the forging dies have moved outwardly soas to no longer engage the workpiece. By repeatedly rotating the ram inincrements, the rotator eventually rotates the ram through a full 360°.

The ram is preferably incrementally rotated after a predetermined numberof parts have been forged. For example, the ram can be incrementallyrotated after forging each part. While the ram can be rotated indifferent degrees, the ram of one embodiment is rotated between 10° and30° and, more preferably, is rotated about 20° about the lengthwiseextending axis during each incremental relative rotation. The ram can berotated in a variety of manners. In one embodiment, for example, a gearcan be operably connected to the ram and a drive member, such as aratchet or a pinion gear, can be driven so as to engage the gear and tocause the gear to rotate, thereby correspondingly rotating the ramrelative to the die assembly.

For control purposes, the forge can also include a sensor for detectingthe incremental relative rotation between the ram and the die assembly.As such, the forge can delay the lengthwise advancement of the ramthrough the passageway defined by the head until after the sensor hasdetected that the ram has been rotated relative to the die assembly.

By rotating the ram through the entire 360°, the shape of the ram,typically a cylindrical shape, is maintained and the ram is preventedfrom developing an oval shape as a result of the forces imparted duringforging operations. Thus, the forge of this embodiment of the presentinvention can more reliably form parts of the predetermined shape over alonger period of time, thereby extending the effective life of the ram.

According to one advantageous embodiment of the present invention, theforge includes a lubrication system for providing a lubricant between atleast some of the forging dies and the ram. By lubricating the forgingdies and the ram, the lubrication system facilitates the relativemovement between the ram and the forging dies which occurs as the ram isalternately advanced and retracted. Preferably, the lubrication systemprovides lubricant while the ram is at least partially retracted and thedie assembly is at least partially removed from the die cavity since thedie assembly and, more particularly, the forging dies will then beexposed beyond the ram.

In one embodiment, the ram defines a plurality of ports opening into thecavity. As such, the lubrication system can inject lubricant through theports so as to provide lubricant between at least some of the forgingdies and the ram. In the embodiments in which the forge also includes arotator for imparting an incremental relative rotation between the ramand the die assembly, the relative rotation between the ram and the dieassembly will also therefore serve to circumferentially distribute thelubricant which has been injected at a number of discrete points in afairly even manner.

The lubrication system can also provide lubricant between the ram andthe head to facilitate relative movement therebetween, i.e., tofacilitate the alternate advancement and retraction of the ram relativeto the head. In this embodiment, either the head, the ram or both thehead and the ram can define at least one circumferentially extendinggroove opening into the passageway defined by the head. As such, thelubrication system can inject lubricant into the circumferential groovefor distribution between the head and ram as the ram is alternatelyadvanced and retracted during forging operations.

As such, the forging apparatus of this embodiment facilitates relativemovement between the ram, the die assembly and the head so as to reducethe wear of the various components and to correspondingly extend theoperational life of the forge. In contrast to conventional wisdom whichdiscouraged the use of lubrication during a continuous forming processfor fear of coating the stock material with a lubricant which mightprevent or impair proper handling and positioning of the stock material,the forging apparatus of this embodiment of the present inventionlubricates the various components of the forge while permitting only aminimal amount of the lubricant to contact the continuous stock materialsuch that subsequent handling and positioning of the continuous stockmaterial is not adversely affected.

As will be apparent, the forming method and apparatus of the presentinvention is extremely versatile and can form a variety of differenttypes of parts from a continuous stock material. According to oneadvantageous embodiment, however, the forming method and apparatus formsspade bits of a predetermined shape. In particular, the spade bit caninclude an elongate shank defining a central longitudinal axis and ablade portion joined at a rear end to one end of the shank. The spadebit can also include a spur extending axially from a forward end of theblade portion, opposite the rear end.

The blade portion of the spade bit of the present invention includes apair of generally flat side segments which extend laterally in oppositedirections from the central longitudinal axis. The side segments definerespective lateral planes which are parallel to each other and thecentral longitudinal axis. The side segments also include respectiveforward cutting edges which are axially offset relative to each other tothereby define an axially advanced forward cutting edge and an axiallyrearward forward cutting edge. According to one advantageous embodiment,the forward cutting edges are axially offset by a predetermined axialoffset, such as between about 0.010 inch and about 0.012 inch. By havingforward cutting edges which are axially offset, the spade bit can moreefficiently engage and remove portions of a workpiece during the boringof a hole. As a result, the longevity of a spade bit having axiallyoffset forward cutting edges is also generally enhanced due to the moreefficient removal of chip swarf during drilling operations.

The side segments of the blade portion of the spade bit of the presentinvention can also include chamfered corner portions which include achamfered edge extending both axially rearward and laterally outwardfrom the respective forward cutting edge. In addition, each chamferedcorner portion can include a chamfered surface which slopes radiallyinward from the respective chamfered edge to a rear edge. By includingchamfered corner portions, the spade bit of the present invention canmore cleanly bore a hole while reducing binding and other frictionalengagement between outer portions of the spade bit and the innerperiphery of the hole, thereby further increasing the efficiency of thedrilling operations.

Regardless of the type of parts formed by the forming method andapparatus of the present invention, the forming method and apparatus caneffectively form a plurality of parts of a predetermined shape from acontinuous stock material without separating the parts until most, ifnot all, of the forming operations have been completed. As a result, theforming method and apparatus of the present invention significantlyincreases the efficiency with which parts of a predetermined shape aremanufactured, as well as the tolerance control and concomitant qualityof the resulting parts. In addition, the forming method and apparatus ofthe present invention effectively decreases the number of partiallyformed parts which are in process at any one time, thereby furtherincreasing the efficiency and decreasing the costs associated with themanufacture of parts of the predetermined shape according to the formingmethod and apparatus of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic plan view of the forming apparatus of oneembodiment of the present invention.

FIG. 2 is a side elevational view of at least portions of the formingapparatus of the embodiment of the present invention illustrated in FIG.1.

FIGS. 3A-3G illustrate the various shapes into which the continuousstock material is formed by the forming method and apparatus of oneadvantageous embodiment of the present invention which is designed tofabricate spade bits.

FIG. 4 is a front elevational view of a spade bit according to oneembodiment of the present invention.

FIG. 5 is a side elevational view of a spade bit of the embodiment ofthe present invention illustrated in FIG. 4.

FIG. 6 is a greatly enlarged fragmentary front elevational view of theblade portion of a spade bit of the embodiment of the present inventionillustrated in FIG. 4.

FIG. 6A is an end view of the spade bit of FIGS. 4-6 when viewed alongthe line 6A—6A of FIG. 4 which illustrates the alignment of the forwardcutting edges of the side segments along a centerline that passesthrough the central longitudinal axis.

FIG. 6B is a fragmentary side view of a portion of a side segment of thespade bit of FIG. 6A illustrating the hook angle and taken along theline 6B—6B of FIG. 6A.

FIG. 7 is a fragmentary cross-sectional side elevational view of aportion of the embodiment of the forming apparatus illustrated in FIG. 1which depicts the straightener, the draw box, the load collet and theindexer in greater detail.

FIG. 8 is a fragmentary cross-sectional side elevational view of anotherportion of the embodiment of the forming apparatus illustrated in FIG. 1which depicts the hex forge and the turning head.

FIG. 8A is a fragmentary cross-sectional plan view taken along line8A—8A of FIG. 8 and illustrating various sensors and monitors associatedwith the hex forge.

FIG. 9 is a fragmentary cross-sectional side elevational view of aportion of the hex forge, wherein the plurality of forging dies havebeen at least partially closed about the continuous stock material, andwherein the upstream turning head clamp is closed.

FIG. 10 is a perspective view of one of the plurality of forging dies ofthe hex forge.

FIG. 11 is a cross-sectional view of the forging die of FIG. 10 as takenalong line 11—11.

FIG. 12A is a cross-sectional end view of the hex forge of FIG. 9 and,more particularly, that portion of the ram which defines the die cavityand the die assembly disposed within the die cavity that includes aplurality of forging dies in an open position as taken along line 12—12of FIG. 9.

FIG. 12B is a cross-sectional end view of the die assembly shown in FIG.12A as taken along line 12—12 of FIG. 9 in which the plurality offorging dies have been at least partially closed about the continuousstock material.

FIG. 13 is a fragmentary cross-sectional end view of a portion of thehex forge which illustrates the toothed gear and associated ratchet forrotating the ram following forging operations as taken along line 13—13of FIG. 9.

FIG. 14A is a fragmentary cross-sectional view of the toothed gear andthe associated ratchet of FIG. 13 which depicts the manner in which theratchet engages the gear such that the gear and, in turn, the ram isrotated in a counterclockwise direction as the ratchet is drivendownwardly.

FIG. 14B is a fragmentary cross-sectional view of the toothed gear andthe associated ratchet of FIG. 13 which depicts the manner in which theratchet disengages from the gear following rotation such that theratchet can be raised upwardly to its home position.

FIG. 15 is a partial fragmentary cross-sectional end view of the hexforge taken along line 15—15 of FIG. 9 which illustrates the lubricationsystem for lubricating the various components of the hex forge.

FIG. 16 is a partial fragmentary cross-sectional side view of the hexforge taken along line 16—16 of FIG. 15 which further illustrates themanner in which lubricant is introduced to the various components of thehex forge.

FIG. 17 is a fragmentary perspective view of a portion of the turninghead including the downstream turning head clamp in which the turninghead dies are in the open position and in which the cover has beenremoved for purposes of illustration.

FIG. 18 is a fragmentary cross-sectional view of a portion of theturning head which illustrates the cooperative engagement of thecontinuous stock material by the turning head dies in order to form aball groove and chamfered edge on the rear portion of the shank of aspade bit.

FIG. 19 is a fragmentary cross-sectional en view of the downstreamturning head clamp taken along line 19—19 of FIG. 17.

FIG. 20 is a fragmentary cross-sectional side view of blade press forgeof one embodiment of the present invention which illustrates theplurality of ports through which lubricant is introduced.

FIG. 20A is a fragmentary cross-sectional plan view taken along line20A—20A of FIG. 20 and illustrating various sensors and monitorsassociated with the blade press forge.

FIG. 21 is a fragmentary perspective view of the alignment sensor fordetecting instances in which the continuous stock material is kinked orotherwise bent such that the forging operations can be halted prior todamaging the blade press forge.

FIG. 22 is a fragmentary cross-sectional view of an adjustable supportfor precisely positioning and supporting the head during forgingoperations taken along line 22—22 of FIG. 20.

FIG. 23 is a fragmentary cross-sectional view of the adjustable supportof FIG. 22 taken along ling 23—23 of FIG. 22.

FIG. 24 is a fragmentary cross-sectional side elevational view of theblade press forge of one embodiment of the present invention wherein theforging dies are in the open position.

FIG. 25 is a partial fragmentary cross-sectional end view of the bladepress forge taken along line 25—25 of FIG. 24 which illustrates thelubrication system for lubricating the various components of the bladepress forge.

FIG. 26 is a partial fragmentary cross-sectional side view of the bladepress forge taken along line 26—26 of FIG. 25 which further illustratesthe manner in which lubricant is introduced to the various components ofthe blade press forge.

FIG. 27 is an enlarged fragmentary cross-sectional side view of aportion of the blade press forge illustrated in FIG. 24 which depictsthe plurality of forging dies in an at least partially closed oroperative position and which also depicts the upstream and downstreamblade press clamps in a closed position.

FIG. 28 is a cross-sectional end view of the die assembly including apair of opposed forging dies and that portion of the ram which definesthe die cavity of the blade press forge as taken along the line 28—28 ofFIG. 27.

FIG. 29 is a greatly enlarged fragmentary cross-sectional end view ofthe pair of opposed forging dies of the blade press forge of theembodiment of the present invention illustrated in FIG. 28 wherein thepair of opposed forging dies are in the at least partially closed oroperative position.

FIG. 30 is a perspective view of a forging die according to oneadvantageous embodiment of the present invention which illustrates theback surface which includes a conical medial section and a pair ofconical lateral sections that are recessed relative to the medialsection.

FIG. 31 is a fragmentary end view of the forging die of FIG. 30illustrating the back surface and, in particular, the respective radiiof the conical medial section and the pair of conical lateral sections.

FIG. 32 is a cross-sectional view of the downstream blade press clamp ofthe blade press of one embodiment of the present invention as takenalong line 32—32 of FIG. 27.

FIG. 33 is an end view of the clamp plate, the downstream blade pressclamp and the frame plate of the blade press carriage of one embodimentof the present invention as taken along line 33—33 of FIG. 24.

FIG. 34 is a side elevational view of the clamp plate, the downstreamblade press clamp and the frame plate of the blade press carriage of oneembodiment of the present invention as taken along line 34—34 of FIG.33.

FIG. 35 is a side elevational view of the spur trimming station, theouter diameter trimming station and the saw station of one embodiment ofthe present invention.

FIG. 36 is a cross-sectional plan view of the spur trimming station, theouter diameter trimming station and the saw station of one embodiment ofthe present invention as taken along line 36—36 of FIG. 35.

FIG. 37 is an end view of the saw station of one embodiment of thepresent invention as taken along line 37—37 of FIG. 35 which illustratesthe advancement of the saw through the continuous stock material.

FIG. 38 is a fragmentary cross-sectional side elevational view of thesaw station and the size stamp station of one embodiment of the presentinvention which illustrates the movement of the size stamp station inthe longitudinal direction.

FIG. 39 is a fragmentary cross-sectional side elevational view of thesaw station and the size stamp station of the embodiment depicted inFIG. 38 which illustrates engagement of a spade-type boring bit by thesize stamp station while the saw station makes a cut at the forward endof a spade-type boring bit as indicated at A.

FIG. 40 is a fragmentary cross-sectional side elevational view of thesaw station and the size stamp station of the embodiment depicted inFIGS. 38 and 39 which illustrates engagement of a spade-type boring bitby the size stamp station while the saw station makes a cut at the rearend of a spade-type boring bit as indicated at B.

FIG. 41 is a cross-sectional end view of the size stamp clamp of oneembodiment of the present invention as taken along line 41—41 of FIG. 40which illustrates the size stamp dies, the alignment fixture and thesurrounding closure.

FIG. 42 is a plan view of a pair of spade-type boring bits formed fromadjacent portions of the continuous stock material which illustrates thecuts made by the saw station at the forward end and the rear end of thespade-type boring bits as designated A and B, respectively.

FIG. 43 is a fragmentary cross-sectional side elevational view of thesaw station and the size stamp station as shown in FIGS. 38-40 whichillustrates the movement of the size stamp station in a downstreamdirection away from the saw station once the spade-type boring bit hasbeen separated from the remainder of the continuous stock material.

FIG. 44 is a fragmentary cross-sectional plan view of the size stampstation of FIG. 43 which illustrates the ejection of the spade-typeboring bit into a collection chute following size stamping operations.

FIG. 45 is a fragmentary cross-sectional side elevational view of anouter diameter trimming and separator station, a size stamping stationand a saw station according to another embodiment of the presentinvention in which an outer diameter trimmer and a snipper are mountedupon a common platform for joint movement.

FIG. 46 is a plan view of the outer diameter trimming and separatorstation, the size stamping station and the saw station of the embodimentof the present invention illustrated in FIG. 44 and taken along line46—46.

FIG. 47 is a plan view of a spade-type boring bit which illustrates thecuts made by the snipper and the cut made by the saw station at thelocations designated C, D and E.

FIG. 48 is a fragmentary cross-sectional view of a rotary actuator ofthe size stamping station of one embodiment taken along line 48—48 ofFIG. 46.

FIG. 49 is a fragmentary cross-sectional side elevational view of thesaw station as depicted more generally in FIGS. 45 and 46 and as takenalong line 49—49 of FIG. 46.

FIG. 50 is a fragmentary cross-sectional view of the saw station showngenerally in FIGS. 45 and 46 taken along line 50—50 of FIG. 49 whichillustrates the manner in which the saw station advances into and out ofthe path of the continuous stock material.

FIG. 51 is a fragmentary cross-sectional side elevational view of ablade press forge of another embodiment of the present invention.

FIG. 52 is a more detailed fragmentary cross-sectional side elevationalview of the blade press forge of the embodiment illustrated in FIG. 51.

FIG. 53 is a fragmentary cross-sectional end view of the blade pressforge of the embodiment depicted in FIGS. 51 and 52 taken along line53—53 of FIG. 51.

FIG. 54 is a fragmentary cross-sectional plan view of the ram supportassembly of the embodiment of the blade press forge illustrated in FIGS.51 and 52 taken along line 54—54 of FIG. 51.

FIGS. 55A-55I are flow charts illustrating the operations performed bythe forming method and apparatus of one embodiment of the presentinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention will now be described more fully hereinafter withreference to the accompanying drawings, in which a preferred embodimentof the invention is shown. This invention may, however, be embodied inmany different forms and should not be construed as limited to theembodiments set forth herein; rather, this embodiment is provided sothat this disclosure will be thorough and complete and will fully conveythe scope of the invention to those skilled in the art. Like numbersrefer to like elements throughout.

Referring now to FIGS. 1 and 2, a forming apparatus 10 according to oneadvantageous embodiment of the present invention is illustrated. Asdescribed in detail hereinbelow and as illustrated in FIGS. 1 and 2, theforming apparatus and associated method forms a plurality of parts froma continuous stock material 12. For purposes of illustration, however,the forming apparatus and method will be primarily described inconjunction with the formation of a plurality of spade bits from acontinuous metal wire, as shown in FIGS. 3-6. However, the formingmethod and apparatus can be adapted to form a variety of other partswithout departing from the spirit and scope of the present invention.For example, the forming method and apparatus of the present inventioncan form drill bits, router bits, fasteners, percussion bits, jigsaw andreciprocating saw blades, impact wrench anvils, coil and ballpointchisels, gears, shafts, screwdriver bits, equalizers beams and actuatorrods as well as other types of parts, including both those parts whichare symmetrical about a central longitudinal axis and those parts whichare not symmetrical about a central longitudinal axis, without departingfrom the spirit and scope of the present invention.

According to the forming method and apparatus 10 of the presentinvention, the plurality of parts are formed from a continuous length ofstock material 12. Typically, the continuous stock material is comprisedof a steel alloy, such as a 1050 carbon steel that has been doubleannealed and has a Rockwell Rb hardness of about 71 to 74. However, thecontinuous stock material can be comprised of any forgeable materialknown to those skilled in the art. For example, the continuous stockmaterial can be comprised of copper, aluminum, titanium, zinc, brass oralloys thereof. In addition, the continuous stock material can becomprised of a combination of materials. For example, the continuousstock material can include metal powder and/or resin disposed within ametallic or plastic carrier tube. Accordingly, the forming method andapparatus of the present invention can form the carrier tube, includingthe metal powder and/or resin disposed therein, into a plurality ofparts of a predetermined shape without departing from the spirit andscope of the present invention. Still further, the continuous stockmaterial could be formed of a plurality of individual parts, potentiallyof greatly different cross-sectional shapes and sizes, which may bejoined, such as by welding or other means, in an end-to-endrelationship.

While principally described hereinbelow as a cold forming method, thecontinuous stock material 12 can be heated prior to the forging step,such as with in-line induction or infrared heating devices, such thatthe forming method is a warm or hot forging method. The temperatureranges to which each of the various materials from which the continuousstock material can be formed must be heated in order to be cold, warm orhot forged depend, among other things, upon the strength and internalproperties of the respective material, and are known to those skilled inthe art. For example, continuous stock material comprised of steelalloys typically have a temperature of between room temperature and 300°F. during cold forging operations, a temperature of between 200° F. and1400° F. during warm forging operations, and a temperature of between1200° F. and 2200° F. during hot forging operations. In addition, theforming method of the present invention which includes a step of hotforging a workpiece is particularly effective to forge workpiecescomprised of a material having a relatively low melting point, such asaluminum, brass, zinc and copper.

Referring now to FIGS. 55A-55I, a flow chart illustrating the operationsperformed by the forming method and apparatus 10 of the presentinvention is illustrated. Once the continuous stock material 12 has beenloaded as shown in block 500 and as described hereinbelow, the remainingoperations of the forming method and apparatus are relativelycontinuous. Accordingly, the operations illustrated by the flow chart ofFIGS. 55A-55I are generally repeated many times. For purposes ofillustration, however, the flow chart of FIGS. 55A-55I begins at a pointin the continuous forming cycle at which each of the forming operationshave been performed on a predetermined portion of the continuous stockmaterial, such that the continuous stock material must now be advanced.

As shown in FIG. 7, the forming apparatus 10 preferably includes anindexer 14 which intermittently advances the continuous stock material12 longitudinally by pushing the continuous stock material apredetermined linear distance in a downstream direction. In order toadvance the continuous stock material, the indexer preferably includesan indexer clamp 16 for securely gripping a portion of the continuousstock material. As illustrated in FIG. 7, the indexer clamp preferablyincludes an annular collet 18 through which the continuous stockmaterial extends. The indexer clamp can also include an annular closure20 which defines an internal cavity within which the collet can bereceived. The shape of the internal cavity defined by the closure ispreferably complimentary to the shape of the collet. For example, thecollet can be generally frustoconical in shape and the internal cavitydefined by the closure can be generally frustoconical in shape. Thus, byurging the closure over the collet, the collet can be closed about thecontinuous stock material as shown in block 502 of FIG. 55A, therebysecurely gripping the continuous stock material.

As will be apparent to those skilled in the art, the closure 20 can beurged or displaced over the collet 18 in a variety of manners. Forexample, the indexer clamp 16 can include an indexer clamp cylinderassembly including an annular piston rod which is operably connected tothe closure and which is disposed within an annular cylinder such that,by hydraulic actuation of the indexer clamp cylinder assembly, theannular piston rod is extended and the closure is urged or axiallydisplaced over the collet such that the collet is closed about thecontinuous stock material 12.

Referring now to FIG. 56, the forming apparatus 10 of the presentinvention also includes a controller 30, operably connected to theindexer clamp 16, for controlling the hydraulic actuation of the indexerclamp cylinder assembly. The controller 30 is preferably implemented bya combination of hardware and software. For example, the controller canbe implemented by a programmable multiaccess controller (PMAC) and oneor more programmable logic controllers (PLCs) which operate under thecontrol of software stored in one or more memory elements to provide themonitoring and control described below. The controller is also operablyconnected to a hydraulic power source and an electrical power source 31for providing and allocating hydraulic and electrical power,respectively, for the forming method and apparatus of the presentinvention as shown schematically in FIGS. 2 and 56 and as describedhereinafter.

As will be described hereinafter, the forming apparatus 10 of thepresent invention preferably includes a number of clamps, other than theindexer clamp 16. In order to advance the continuous stock material 12,however, all of the clamps, other than the indexer clamp, should beopened such that the continuous stock material is free to move in adownstream longitudinal direction therethrough. Thus, as shown in blocks504-508 of FIG. 55A, once the controller 30 has closed the indexer clampabout the continuous stock material and all of the other clamps havebeen opened, the indexer 14 advances the indexer clamp longitudinally bya predetermined linear distance from the initial position shown in solidlines in FIG. 7 to the final position shown in dashed lines. As a resultof the secure gripping of the continuous stock material by the indexerclamp, however, the indexer also effectively advances the continuousstock material longitudinally by the same predetermined linear distance.

The indexer 14 can longitudinally advance the indexer clamp 16 in anumber of manners without departing from the spirit and scope of thepresent invention. In the exemplary embodiment shown in FIG. 7, however,the indexer includes an indexer cylinder assembly 22. As described inU.S. Pat. No. 5,842,267 (the '267 patent), the indexer cylinder assemblycan be positioned in-line and, as such, could include an annular pistonrod disposed within an annular hydraulic cylinder so that the continuousstock material 12 could extend therethrough. In order to reduce thelength of the forming apparatus 10 and to reduce the complexity of theindexer cylinder assembly, however, the indexer cylinder assembly of theembodiment of FIG. 7 can be mounted beneath the platform 17 whichsupports the indexer clamp. As shown, the indexer cylinder assemblyincludes a piston cylinder 26 and a piston rod 24 which extendsoutwardly from the piston cylinder. The piston rod is operably connectedto the indexer clamp through an opening in the platform such that, uponhydraulic actuation of the indexer cylinder assembly, the annular pistonrod and, therefore, the indexer clamp is urged in a downstreamlongitudinal direction. Alternatively, the indexer can include an ACservomotor and an associated ballscrew for longitudinally advancing theindexer clamp. In order to facilitate longitudinal movement of theindexer clamp, the indexer clamp and, more typically, the indexerplatform is preferably mounted upon a pair of longitudinally extendingrails 25 which limit the indexer clamp to longitudinal movement.

The indexer 14 also preferably includes an indexer monitor 28 formonitoring the longitudinal distance by which the indexer has advancedthe continuous stock material 12. In one advantageous embodiment, theindexer monitor includes a glass scale, such as an RSF Elektronik typeMSA 6706 glass scale, which is operably connected to the indexerplatform 17 for effectively measuring the longitudinal displacement ofthe indexer clamp 16 as a result of the downstream longitudinalextension of the piston rod 24.

The controller 30 is also operably connected to the indexer cylinderassembly 22 and the indexer monitor 28 for controlling the hydraulicactuation of the indexer cylinder assembly. According to the presentinvention, once the controller determines that the indexer 14 haslongitudinally advanced the continuous stock material 12 by thepredetermined linear distance, the controller terminates furtherextension of the piston rod by halting the hydraulic actuation of theindexer cylinder assembly.

The forming apparatus 10 also preferably includes a straightener 32which includes a series of aligned rollers 34 for straightening thecontinuous stock material 12 prior to forming the continuous stockmaterial into a plurality of parts. In the illustrated embodiment, thestraightener includes a two-plane straightener which has a plurality ofaligned rollers disposed in two mutually perpendicular planes such thatthe continuous stock material is straightened in each of the planes.Accordingly, as the indexer 14 intermittently advances the continuousstock material in a downstream longitudinal direction, the stockmaterial is drawn from a supply reel 33 and is straightened by passingthrough the straightener.

Once the controller 30 has terminated the longitudinal advancement ofthe continuous stock material 12 by the indexer 14, another clamp,downstream of the indexer clamp 16, is closed to securely grip anotherportion of the continuous stock material. In the embodiment illustratedin FIGS. 1 and 2 and in block 510 of FIG. 55A, the forming apparatus 10includes an upstream turning head clamp 44 which is adapted to be closedabout the continuous stock material following the intermittentadvancement of the continuous stock material by the indexer. However,the forming apparatus could include other clamps, not associated with aturning head 45, in order to securely grip another portion of thecontinuous stock material following the intermittent advancement of thecontinuous stock material.

As described above in conjunction with the indexer clamp 16 and as shownin FIG. 8, the upstream turning head clamp 44 can include an annularcollet 46 through which the continuous stock material 12 extends and anannular closure 48 which defines an internal cavity which is adapted toat least partially receive the collet. The upstream turning head clampalso includes a turning head cylinder assembly comprised of an annularcylinder and an annular piston rod disposed within the annular cylinder.According to the present invention, the controller 30 can hydraulicallyactuate the turning head cylinder assembly such that the annular pistonrod is extended. As a result of the operable connection of the pistonrod to the annular closure, the extension of the piston rod will urgethe closure about the collet in order to at least partially close thecollet about the continuous stock material such that the upstreamturning head clamp securely grips a portion of the continuous stockmaterial as shown in FIG. 9.

As shown in blocks 512 and 514, once the upstream turning head clamp 44has been closed for a predetermined dwell time, such as 0.1 seconds inone advantageous embodiment, the controller 30 opens the indexer clamp14 such that the collet 18 is opened and the continuous stock material12 is free to move longitudinally therethrough. For example, thecontroller can hydraulically retract the annular piston rod of theindexer clamp cylinder assembly such that the closure 20 is disengagedfrom the collet.

As shown in block 516 of FIG. 55C, the indexer 14 and, moreparticularly, the indexer clamp 16 can then be retracted so as to returnthe indexer clamp to an initial or rest position, as shown in solidlines in FIG. 7, at the same time as a portion of the continuous stockmaterial 12 is being formed. In particular, the controller 30 preferablyhydraulically actuates the indexer cylinder assembly 22 in order toretract the piston rod 24 and, therefore, the indexer clamp at a firstpredetermined rate.

Referring now to FIG. 7, the forming apparatus 10 also preferablyincludes a draw box 36 having draw dies 38 through which the continuousstock material 12 is drawn in order to appropriately size the continuousstock material and to effectively remove the memory of the previouslycoiled stock material. As known to those skilled in the art, the drawbox can also include a predraw die 40 in order to at least partiallyreduce the size of the continuous stock material and can include asource of lubricant 42 between the predraw die and the draw die in orderto facilitate the drawing of the continuous stock material.

The draw box 36 is adapted to move longitudinally in conjunction withthe annular piston rod 24 of the indexer cylinder assembly 22 asdescribed below. Thus, the draw box preferably includes one or moreslides 37 which ride upon and cooperate with a pair of longitudinallyextending, parallel rails or tracks 39. As shown in FIG. 7, the indexercylinder assembly is preferably double acting. Thus, upon retraction ofthe annular piston rod as shown in block 516 of FIG. 55C, the draw boxis also urged or axially displaced in an upstream longitudinaldirection. As such, the draw box is urged or pushed over the continuousstock material so as to effectively draw and, therefore, size thecontinuous stock material prior to subsequent forming operation.

As illustrated, the draw box 36 is typically positioned downstream ofthe straightener 32 such that the finished surface of the continuousstock material created by the draw box is not adversely affected by thestraightener rolls 34. However, the draw box can be located upstream ofthe straightener in order to prevent the draw dies 38 fromdisadvantageously kinking or otherwise creating slight bends in thecontinuous stock material, if so desired.

As will be apparent to those skilled in the art, the draw box 36 can bedesigned to draw the continuous stock material 12 to any reasonable sizedesired. In the embodiment in which the forging method and apparatus 10is adapted to fabricate spade bits 410, the draw box and, moreparticularly, the draw die 38 is preferably designed such that the sizeor diameter of the drawn stock material can be varied based upon theouter diameter of the blade portion 418 of the resulting spade bit, asexemplified by the following table:

SPADE BIT ORIGINAL WIRE DRAWN WIRE DIAMETER DIAMETER DIAMETER 1⅜″-1½″0.530″ 0.525″ 1⅛″-1¼″ 0.490″ 0.484″ {fraction (15/16)}″-1″ 0.415″ 0.410″¾″-⅞″ 0.385″ 0.375″ {fraction (9/16)}″-{fraction (11/16)}″ 0.325″ 0.320″⅜″-½″ 0.294″ 0.284″

While the indexer clamp 16 is being retracted, the forming method andapparatus 10 of the present invention preferably forges a portion of thecontinuous stock material 12 into a first predetermined shape. Forexample, for the illustrated embodiment of the forming method andapparatus which is adapted to form a plurality of spade bits 410, theforming method and apparatus can form a portion of the continuous stockmaterial so as to have a hexagonal cross-sectional shape, therebyforming the rear portion 416 of the shank 412 of the resulting spadebit.

According to the present invention, the forming apparatus 10 includes aforge and, in one advantageous embodiment, a hex forge 50 for forming aportion of the continuous stock material 12 into the first predeterminedshape, namely, a hexagonal cross-sectional shape as shown in FIG. 3A. Asshown in FIGS. 8-12, the hex forge preferably includes a die assemblyhaving a plurality of forging dies 52 disposed about the continuousstock material. For example, the plurality of forging dies of oneembodiment includes six forging dies which cooperate to define a cavitywhich, in turn, defines at least a portion of the predetermined shape ofthe resulting part, such as the rear portion 416 of the shank 412 of thespade bit 410 which has a hexagonal cross-sectional shape.

The plurality of forging dies 52 can be at least partially disposedwithin an alignment fixture 54, such as a spider, which maintains theforging dies in a predetermined aligned relationship. See, for example,FIGS. 12A and 12B. Thus, the combination of the plurality of forgingdies and the alignment fixture comprise a hex forge die assembly. Asdescribed hereinafter, the die assembly has a predetermined shape, suchas a predetermined frustoconical shape in one advantageous embodiment.

As shown in FIGS. 8-10, the hex forge die assembly is preferablyspring-loaded, such as with springs 56. As shown, the springs extend ina radial direction within the alignment fixture 54 and are at leastpartially disposed within respective pockets 58 defined by the forgingdies. Accordingly, the springs urge the forging dies in a radiallyoutward direction relative to the alignment fixture, such that theforging dies are in an open position, as shown in FIG. 8, in the absenceof additional countervailing forces.

The forging apparatus 10 and, more particularly, the hex forge 50 ofthis aspect of the present invention also includes means, such as thedie housing 60 of the die press ram 61, for radially closing theplurality of forging dies 52. As described in detail below, the forgingdies move radially inward in a predetermined direction shown by thearrows of FIGS. 9 and 11 upon relative movement between the ram and theplurality of forging dies.

At least one and, more preferably, each forging die 52 advantageouslyincludes a contact surface 62 which defines a portion of the cavitythrough which the continuous stock material 12 extends. Each contactsurface is adapted to contact and shape the workpiece into thepredetermined shape defined by the cavity. As shown in FIGS. 10 and 11,the contact surface of at least one of the forging dies preferablydefines a contact plane 64 which is oblique to the predetermineddirection in which the forging dies are closed. Thus, the contact planesof the forging dies impart both axial and radial forces to the workpiecewhich, in turn, result in compressive, tensile and shear stresses withinthe workpiece during the deformation process. The resulting compressiveand shear force components deform the workpiece outwardly into thepredetermined shape defined by the forging dies. More particularly, theresulting compressive and shear force components deform the workpieceplastically and irreversibly into the predetermined shape defined by theforging dies in the closed or operative position.

More particularly, an angle 66 is defined between the respective contactplanes and a reference plane 68 perpendicular to the predetermineddirection in which the forging dies move as shown in FIG. 11. In apreferred embodiment, the angle is between about 10° and about 20° and,in one exemplary embodiment, is about 15°.

As used herein, the term “compressive force” includes those forces inthe predetermined direction in which the forging dies 52 move, and theterm “shear force” includes those lateral forces which tend to deformthe workpiece radially outward. Thus, for a given amount of inputenergy, the amount of shear force and compressive force imparted to theworkpiece increases and decreases, respectively, as the angle 66 definedbetween a respective contact plane 64 and the reference plane 68increases. Likewise, for a given amount of input power, the amount ofshear force and compressive force imparted to the workpiece decreasesand increases, respectively, as the angle defined between a respectivecontact plane and the reference plane decreases.

Those portions of the workpiece which are subjected to shear force, andhence shear stress, are more readily deformed since the shear strengthof most common workpieces, i.e., most metallic materials, issignificantly less than the compressive strength of the same material.Typically, the shear strength of metallic materials is approximately 60%of the compressive strength of the same material. For example, duringthe formation of a spade bit according to the forming method andapparatus 10 of the present invention, both side segments are preferablysubjected to relatively high shear stresses for producing the maximumlateral displacement from a continuous stock material 12 of the smallestinitial diameter.

Thus, significantly less input energy is required to deform a workpiecewith shear forces than with compressive forces. In addition, theapplication of shear forces which more readily deform a workpieceradially outward allows the ratio of the thickness of a part to thewidth or diameter of a part to be decreased such that thin parts havinga relatively large diameter, such as a spade bit, can be readily forgedaccording to this aspect of the present invention. Accordingly, thisaspect of the present invention enables the ratio of the newly generatedproduct surface area to a minimum product thickness to be optimized.

However, the application of shear force to deform a workpiecesignificantly increases the forces which the forging dies 52, the diehousing 60 and the remainder of the ram 61 must withstand during theforging process and, accordingly, has been avoided in conventionalforging processes in which the forging dies are closed in a rectilinearmanner to impart compressive forces on the workpiece. In order towithstand the increased forces, the plurality of forging dies and thedie housing are comprised, in one preferred embodiment, of a high speedsteel and, more preferably, are comprised of CPM® REX™ M4 high speedsteel, or an equivalent, marketed by Colt Industries Crucible SpecialtyMetals Division of Syracuse, New York and described in more detail in apublication entitled Crucible Data Sheet by Colt Industries CrucibleSpecialty Metals Division bearing document number D88 308-5M-776.

As also shown in FIGS. 8, 9, 12A and 12B, the means for closing theplurality of forging dies 52 preferably includes a die housing 60 whichdefines an internal cavity 70 therein. In the illustrated embodiment inwhich the die housing is separate from the remainder of the ram 61, thedie housing is generally press fit into a correspondingly shaped cavitydefined by the ram and opening through the forward end of the ram.Alternatively, the ram can be integrally formed such that the die cavitydefined by the ram and opening through the forward end of the ram servesas the die housing. In either embodiment, the internal cavity of the diehousing is preferably shaped and sized in a complimentary fashion to theshape and size of the die assembly. For example, the die housing candefine an internal cavity having a frustoconical shape in order toreceive and circumferentially encompass a frustoconical die assembly.Thus, by advancing or urging the ram and, more particularly, the diehousing over the die assembly, the die housing forces the plurality offorging dies radially inward so as to close about the continuous stockmaterial 12 which extends therethrough. The strength of the die assemblyand its resulting ability to withstand forces generated during thedeformation of the continuous stock material with axial and compressiveforces which, in turn, generate compressive, tensile and shear stressesis further enhanced by the radial direction in which the die assembly isclosed and the surrounding relationship of the die housing and theremainder of the ram to the die assembly.

According to one advantageous embodiment shown in FIGS. 10 and 11, eachforging die 52 includes not only an inner contact surface 62 forcontacting and shaping the workpiece, but also an opposed outer or backsurface 63 having a predetermined shape for operably contacting the diehousing 60. The predetermined shape of the outer surface of each forgingdie is preferably different than the predetermined shape of the internalcavity 70 of the die housing when the plurality of forging dies are inthe open position as shown in FIGS. 8 and 12A. However, the forging diesnot only move radially inward, but also rotate in the general directionindicated by arrow 67 in FIG. 11 upon insertion into the die housing.Thus, the predetermined shape of the outer surface of each forging diepreferably corresponds to the predetermined shape of the internal cavityof the die housing once the forging dies are in the operative or closedposition as shown in FIGS. 9 and 12B.

In order to fabricate a plurality of parts from a continuous stockmaterial according to the forming method and apparatus 10 of the presentinvention, the hex forge 50 is preferably designed such that thecontinuous stock material 12 can extend longitudinally therethrough. Inparticular, the plurality of forging dies 52 preferably define an entryport 72 and an exit port 74 which open into the internal cavity definedby the forging dies such that the continuous stock material can extendlongitudinally therethrough. In addition, the die housing 60 preferablyhas an annular configuration so as to permit the continuous stockmaterial to also extend therethrough.

The hex forge 50 also preferably includes means, such as a hydraulicallyactuated die press 76, for longitudinally advancing the ram 61,including the die housing 60, over the plurality of forging dies 52 suchthat the forging dies are radially closed about the continuous stockmaterial 12. In order to fabricate a plurality of parts from acontinuous stock material, the die press of one advantageous embodimentshown in FIGS. 8 and 9 includes an annular piston rod 78 disposed withinan annular cylinder 80 which, in turn, defines a lengthwise extendingopening through which the continuous stock material extends. Inparticular, the annular piston rod and the associated piston preferablyhave a central hole bored therethrough which enables the continuousstock material to pass through the die press. The annular piston rod ispreferably operably connected to the die press ram 61 such that thecontroller 30 can hydraulically actuate the die press so as tolongitudinally advance the annular piston rod and, correspondingly, theram as shown in FIGS. 8 and 9 and as described in block 518 of FIG. 55B.

As shown in FIGS. 8 and 9, the hex forge 50 also includes a head 81which defines a passageway that extends longitudinally through at leasta forward portion of the head. Preferably, the forward portion of theram 61 and the passageway defined by the head have the same shape, i.e.,cylindrical, and are sized such that an interference fit is maintainedbetween the head and the forward portion of the ram. As such, thepassageway defined by the head serves to guide the ram as the ram islongitudinally advanced and retracted.

As shown in FIG. 9, the hex forge 50 preferably includes a frame plate82 and a wear plate against which the plurality of forging dies 52 arebutted, thereby preventing longitudinal advancement of the forging dies.Accordingly, the longitudinal advancement of the annular piston rod 78forces the ram 61 and, more particularly, the die housing 60 over theforging dies such that the forging dies are radially closed about thecontinuous stock material 12. While the pressure or force required tourge or axially displace the die housing over the forging dies will varydepending upon the processing conditions, including the type of materialfrom which the continuous stock material is formed and the size andshape of the resulting part, a hydraulic press, such as a 500 ton press,has produced spade bits of the present invention from 1050 carbon steel.

Although the die press 76 of the illustrated embodiment includes anannular cylinder 80 and an annular piston rod 78, the die press caninclude other means of urging or axially displacing the die housing 60over the plurality of forging dies 52. For example, the hex forge 50 ofan alternative embodiment can include a plurality of hydraulic cylinderassemblies disposed concentrically about the continuous stock material12. According to this embodiment, each of the hydraulic cylinderassemblies may be operably connected to the die housing such that thedie housing can be urged over the plurality of forging dies uponactuation of the hydraulic cylinder assemblies.

During the forging operation, the continuous stock material 12 growslongitudinally. In particular, the continuous stock material grows inboth an upstream and a downstream longitudinal direction. Thus, theforging apparatus 10 of the present invention preferably includescompensating means for compensating for the longitudinal growth of thecontinuous stock material. With respect to the hex forge 50 illustratedin FIGS. 8 and 9, the upstream longitudinal growth of the continuousstock material is returned in an upstream direction toward the supplyreel 33.

In contrast, the downstream longitudinal growth of the continuous stockmaterial 12, i.e., the longitudinal growth of the continuous stockmaterial between the portion of the continuous stock material which isformed and the fixed portion of the continuous stock material which isclamped by the upstream turning head clamp 44, is compensated for orabsorbed by mounting the plurality of forging dies 52, the ram 61including the die housing 60, the head 81, the frame plate 82 and thedie press 76 upon a carriage 84 which is adapted to move longitudinally.In particular, the hex forge 50 preferably includes a carriage which isadapted to move from an initial or rest position in an upstreamlongitudinal direction by a distance equal to the downstreamlongitudinal growth of the continuous stock material between the portionof the continuous stock material which is formed and the fixed portionof the continuous stock material which is clamped by the upstreamturning head clamp. As a result, the hex forge permits the plurality offorging dies to remain closed about the same portion of the stockmaterial during each respective forming step, while permittinglongitudinal growth of the continuous stock material in bothlongitudinal directions, i.e., in both the upstream and downstreamlongitudinal directions.

As illustrated in FIG. 8, the carriage 84 can include slides 86 whichare mounted upon a pair of parallel, longitudinally extending tracks 88in order to facilitate longitudinal movement of the carriage. Inaddition, the carriage can be longitudinally biased, such as by ahydraulic spring or other biasing means 90, to prevent excessivemovement of the carriage in the upstream longitudinal direction. Inparticular, the longitudinal biasing of the carriage encourages theportion of the continuous stock material 12 which is formed to expandlaterally within the cavity defined by the plurality of forming dies 52so as to more completely fill the cavity defined thereby.

While the same bias force can be applied to the carriage 84 during theentire forging operation, the controller 30 can be operably connected tothe biasing means 90 in order to control the bias force applied thereby.For example, the controller can include a predetermined bias schedulewhich defines the bias force to be applied over time. Thus, thecontroller and the biasing means can increase the magnitude of the biasforce over time so as to further encourage lateral expansion of theportion of the continuous stock material 12 which is formed.

The forming apparatus 10 and, more particularly, the hex forge 50 alsopreferably includes a hex press position monitor 92, such as an MTSTemposonics® LP position sensing system, for monitoring the longitudinalposition of the carriage 84 as shown in FIG. 8A and in block 520 of FIG.55B. The controller 30 is also operably connected to the hex pressposition monitor for determining if the upstream longitudinal movementof the carriage equals or exceeds a predetermined longitudinal growththreshold. Since the longitudinal movement of the carriage equals thelongitudinal growth of the continuous stock material 12 in thedownstream longitudinal direction which, in turn, is directly related tothe extent to which the continuous stock material has been forged, thecontroller and associated hex press position monitor can effectivelymonitor the forging operations by measuring the longitudinal growth ofthe continuous stock material. The controller can then terminate forgingoperations, such as by ceasing the hydraulic actuation of the die press76, once longitudinal growth of the continuous stock material is atleast as great as a predetermined longitudinal growth threshold, asshown in block 522.

Once the controller 30 has terminated the forging operations, thecontroller can retract the ram 61, thereby withdrawing the die housing60 from the plurality of forging dies 52, such as by hydraulicallyretracting the annular piston rod 78 at least partially within theannular cylinder 80. As described above, the die assembly includes aplurality of springs 56, one of which is associated with each of theplurality of forging dies, for urging the respective forging diesradially outward. Accordingly, upon the removal of the die housing fromthe plurality of forging dies, the plurality of forging dies are openedsuch that the continuous stock material 12 can move longitudinallytherethrough.

The hex forge 50 can also include a positioner, such as the hydraulicactuator 90 which also serves as the biasing means, that is operablyconnected to the carriage 84 for repositioning the carriage to apredetermined initial or rest position once a plurality of forging dies52 have been opened. As shown in FIG. 8A, the predetermined initialposition is defined by the end of a threaded rod 96 which is fixed tothe underlying table 98 by a fixed nut assembly 99. Thus, the controller30 can direct the hydraulic actuator to reposition the carriage suchthat the carriage is returned to the predetermined rest position forsubsequent forging operations. As will be apparent to those skilled inthe art, the positioner of the hex forge can be implemented in a numberof other fashions, such as with an AC servomotor and an associatedballscrew, without departing from the spirit and scope of the presentinvention.

The hex forge 50 of the illustrated embodiment also preferably includesa die press monitor 100, such as another MTS Temposonics® LP positionsensing system or a glass scale, for monitoring the relative position ofthe annular piston rod 78 of the die press 76. As described above, thecontroller 30 is operably connected to the die press monitor so as todetermine if the annular piston rod has been retracted to apredetermined initial position. As shown in blocks 524-528 of FIG. 55B,if the annular piston has not been retracted to the predeterminedinitial position, the controller continues the retraction of the annularpiston. Once the annular piston has been retracted to the predeterminedinitial position, however, the controller halts the retraction of theannular piston.

In addition to terminating forging operations upon detecting that thecontinuous stock material 12 has grown by a predetermined longitudinalamount, the forging apparatus 10 and, more particularly, the controller30 preferably increases the rate at which the indexer 14 is retractedonce forging operations are terminated. In particular, the controllerpreferably retracts the piston rod 24 of the indexer cylinder assembly22 and, as a result, the indexer clamp 16 at a second predetermined rateonce the forging operations have terminated. Typically, the secondpredetermined rate is greater than the first predetermined rate. Duringthe retraction of the indexer clamp, the controller, in response tosignals provided by the indexer monitor 28, preferably monitors therelative position of the indexer clamp and halts further retraction ofthe annular piston rod and the indexer clamp once the indexer clamp isat a predetermined retracted position, as shown in blocks 530-534 ofFIG. 55C. While the predetermined retracted position can be the same asthe predetermined initial or rest position of the indexer, the formingapparatus of one advantageous embodiment preferably retracts the indexerto a retracted position which is longitudinally rearward of the initialor rest position by a relatively small predetermined longitudinaldistance, such as 0.005 inch, in order to compensate for additionalmovement of the continuous stock material once the upstream turning headclamp 44 is released.

As shown in block 533 of FIG. 55B, once the controller 30 has terminatedforging operations and retracted the ram 61 of the hex forge 50, the ramcan be rotated relative to the plurality of forging dies 52 such thatthe wear and degradation of the die housing 60 occasioned by therelative motion of the ram and the plurality of forging dies is spreadrelatively evenly about the circumference of the die housing. In thisregard, the hex forge can include a rotator for imparting relativerotation between the ram and the die assembly. As shown in FIG. 13, forexample, the rotator includes a toothed gear 102 mounted to the ram anda drive member 103, such as a rod which carries a pawl 103 a, whichengages the gear and causes the gear and, in turn, the ram to rotate. Asshown, the drive member can be mounted to the carriage 84 and, moreparticularly, mounted upon a rear bolster plate of the die press.Although the drive member can be actuated in a variety of manners, thedrive member of the illustrated embodiment can be extended and retractedby means of a hydraulic actuator 105. In this regard, the hydraulicactuator can extend the drive member by advancing the drive member in adownward direction as depicted in FIG. 13 such that the pawl can engagethe gear as shown in FIG. 14A and cause the gear to rotate by apredetermined angular amount in the counterclockwise direction. Once thegear has been rotated, the drive member is retracted by the hydraulicactuator. As shown in FIG. 14B, the pawl is disengaged from the gear bypivoting the pawl away from the gear. Typically the pawl is pivoted awayfrom the gear since the gear is adapted to rotate in only one direction,i.e., the counter-clockwise direction in the embodiment of FIG. 13, suchthat attempts to retract the drive member will overcome the spring forcewhich urges the pawl into engagement with the gear and permit the pawlto pivot out of engagement with the gear. As will be apparent, a varietyof other drive members, such as pinion gears or the like, can beutilized to rotate the gear and, in turn, the ram without departing fromthe spirit and scope of the present invention.

Preferably, the ram 61 is incrementally rotated after a predeterminednumber of parts have been formed, such as after each part has beenformed. Although the ram can be rotated by different predeterminedamounts, the ram is generally rotated between 10° and 30° and, moretypically, by about 20°. By repeatedly incrementally rotating the ram,however the ram will eventually be rotated completely about the dieassembly, that is, through an entire 360°. As such, the rotation of theram relative to the die assembly will more evenly distribute the wearabout the die cavity. In addition, the rotation of the ram relative tothe die assembly will maintain the generally cylindrical shape of theram and substantially prevent the forward end of the ram from assumingan oval shape or from otherwise being deformed during forging operationsas has occurred to rams of conventional forges.

Although not illustrated, the hex forge die assembly could be rotated inaddition to or instead of rotating the ram 61. In addition to promotingmore even wear of the die housing 60, rotation of the hex forge dieassembly would also allow different parts to be forged into respectivepredetermined shapes which are disposed at different angularorientations relative to the continuous stock material, thereby furtherincreasing the versatility of the forming method and apparatus 10 of thepresent invention.

The hex forge 50 can also include a sensor 107 for detecting rotation ofthe ram 61 relative to the die assembly. By monitoring the rotationsensor to the controller 30, the controller can determine if the ram hasbeen rotated relative to the die assembly following a forging operationand can prevent further forging operations until the ram has beenappropriately rotated.

The hex forge 50 can also include a lubrication system 109 as shown inFIGS. 15 and 16 for providing lubricant to the die assembly, the ram 61including the die housing 60 and the head 81. Typically, the lubricantis an oil, such as machine way lube. However, the lubrication system canapply other lubricants, if so desired. According to this embodiment, theplurality of ports 111 are defined through the head and the ram so as toopen into the die cavity within which the die assembly is inserted. Byinjecting lubricant through these ports, the lubrication system cantherefore provide lubricant to the back surfaces 63 of the forging dies52.

The controller 30 typically controls the operation of the lubricationsystem 109, such as the pneumatically actuated solenoid valve 109 a andthe servovalves 109 b which control the flow of lubricant in theillustrated embodiment. Typically, the controller directs thelubrication system to provide lubricant following each forging operationby injecting lubricant through the ports 111 once the ram 61 has beenlongitudinally retracted and while the back surfaces 63 of the forgingdies 52 are at least somewhat exposed. See block 531 of FIG. 55B. Whilelubricant is injected at a plurality of discrete ports, such as threeports, the subsequent rotation of the ram relative to the die assemblyserves to distribute the lubricant relatively evenly between the ram andthe back surfaces of each of the forging dies.

The lubrication system 109 can also provide lubricant between the head81 and the ram 61 in order to facilitate the lengthwise advancement andretraction of the ram within the passageway defined by the head. In thisregard, another port 113 can be defined through the head such thatlubricant injected through this additional port is spread over the outersurface of the ram and the inner surface of that portion of the headwhich defines the passageway. To facilitate even distribution of thelubricant about the entire circumference of the ram, the head preferablydefines a circumferentially extending groove 115. By injecting lubricantinto the circumferential groove, lubricant is effectively applied aboutthe entire circumference of the ram, thereby evenly lubricating the ram.Alternatively, the ram can define the circumferential groove instead ofor in addition to the head, if so desired.

As described above, the controller 30 typically directs the lubricationsystem 109 to inject lubricant once the ram 61 has been fully retracted.However, lubricant can be injected at other times during the forgingprocess, if desired. Thus, the lubrication system of the forge of thisadvantageous embodiment can repeatedly lubricate the various componentsof the forge in order to reduce wear and increase the effective life ofthe components without applying enough lubricant to the continuous stockmaterial 12 that the continuous stock material becomes difficult to gripduring downstream operations.

The forging method and apparatus 10 can also include a sensor 85, suchas a photoelectric eye or sensor, for monitoring the continuous stockmaterial 12 which exits the hex forge 50. As such the sensor istypically positioned immediately downstream of the hex forge. The sensoris typically adapted to monitor the hex portion that has been formed bythe hex forge and to notify the controller 30 if the hex portion has notbeen properly formed such that the controller can halt further forgingoperations to enable the forging process to be corrected.

The continuous stock material 12 preferably includes one or moreregistration features 104 disposed at predetermined locations along itslength. See, for example, FIGS. 3A-3G. While the continuous stockmaterial can include the registration features prior to commencing theforming method of the present invention, the forming method andapparatus 10 typically creates or forms the registration features duringthe fabrication process. For example, while the upstream turning headclamp 44 is securely gripping a fixed portion of the continuous stockmaterial, the forming apparatus 10 of the illustrated embodimentpreferably forms a predetermined registration feature on the continuousstock material. The registration feature is preferably defined betweeneach of the plurality of parts which will be formed from the continuousstock material. However, the registration feature can be formed at otherpredetermined locations without departing from the spirit and scope ofthe present invention. In addition, the forming method and apparatus 10can form the registration features in other manners, such as by printinga plurality of longitudinally spaced apart lines on the continuous stockmaterial or by punching a hole in a predetermined portion of each part.

While the turning head 45 is described hereinafter as forming theregistration feature 104 following the initial forging operation, theturning head can form the registration feature at any time while theupstream turning head clamp 44 securely grips the fixed portion of thecontinuous stock material 12 without departing from the spirit and scopeof the present invention. As depicted in FIGS. 8, 17 and 19, the turninghead preferably includes a downstream clamp 47 for securely gripping aportion of the continuous stock material 12. As such, prior to formingthe registration feature, the downstream clamp preferably engages thestock material and thereafter holds the continuous stock material untilthe formation of the registration feature is complete. While thedownstream clamp is depicted so as to be pneumatically actuated, theturning clamp can be actuated in other manners, such as hydraulicactuation, without departing from the spirit and scope of the presentinvention. In addition, the downstream turning head clamp can beembodied in many different forms so long as the downstream turning headclamp securely grips the continuous stock material so as to prevent thecontinuous stock material from vibrating while the registration featureis formed.

According to one embodiment illustrated in FIGS. 8, 17 and 18 and shownin block 529 of FIG. 38B, the turning head 45, such as a turning headmanufactured and sold by Eubama Company of Germany, preferably includesa pair of turning head dies 106 and an associated motor 108 which isadapted to rotate the dies about the continuous stock material 12. Theturning head is also adapted to advance the dies in a radially inwarddirection so as to machine predetermined features into the continuousstock material. For example, the turning head dies can be shaped so asto machine a ball groove 110 within the hexagonally shaped rear portion416 of the shank 412 of a spade bit 410. In addition, the turning headdies can be shaped so as to machine a chamfered edge 112 on the rearmostportion of the shank of a spade bit. In forming the chamfered edge onthe rearmost portion of the shank of the spade bit, the turning headand, in particular, the turning head dies can also form a groove 114having a sidewall which extends perpendicular to the longitudinal axisof the continuous stock material. As described hereinbelow and as shownin FIG. 3B, the sidewall can thereafter serve as the registrationfeature 104 during subsequent forming operations. As shown in FIGS. 8and 17, the turning head can also include one or more blowers 49 whichdirect a stream of air past the stock material so as to remove the chipsand other debris prior to further processing the stock material.

During the initial forming operation depicted in blocks 518-528, severaladditional operations can be performed concurrently by the formingmethod and apparatus 10 of the present invention. These concurrentlyperformed operations are performed, however, on different ones of theparts into which the continuous stock material 12 is formed. Inaddition, the types of concurrently performed operations will varydepending upon the type of part which is fabricated. For a formingmethod and apparatus adapted to fabricate a plurality of spade bits 410from a continuous stock material, however, the spur portion 430 of afirst spade bit can be trimmed at the same time as the outer diameter ofanother spade bit is trimmed. As described hereinbelow, the continuousstock material is still interconnected during these trimming operations.Downstream of and concurrent with these trimming operations, thecontinuous stock material can be separated into a plurality of discreteparts and, if desired, can be subjected to in-line heat treating eitherbefore or after separating the continuous stock material into aplurality of discrete parts.

In order to trim the spur portion 430 of a spade bit 410, the formingmethod and apparatus 10 of the present invention includes a spurtrimming station 116 through which the continuous stock material 12passes following the forging operations. As shown in FIGS. 35 and 36,the spur trimming station includes a spur trimming station platform 118and a positioner for controllably positioning the spur trimming stationplatform such that the appropriate portions of a respective part will betrimmed. While the spur trimming station could be positioned in avariety of manners, such as with an AC servomotor and an associatedballscrew, without departing from the spirit and scope of the presentinvention, the positioner of one embodiment includes a hydrauliccylinder assembly 120 including a cylinder 122 and a piston rod 124which is operably connected to the spur trimming station platform.

As shown in FIG. 36, the spur trimming station 116 also preferablyincludes a registration monitor 126, such as a photoelectric eye orsensor, which monitors the continuous stock material 12 during theintermittent advancement of the continuous stock material by the indexer14. The registration monitor is adapted to detect each registrationfeature 104 defined by the continuous stock material as the continuousstock material is advanced. The spur trimming station also includes aposition monitor 128, such as an MTS Temposonics® LP position sensingsystem, for monitoring the position of the spur trimming stationplatform 118.

Both monitors are operably connected to the controller 30. Thecontroller is also operably connected to the indexer monitor 28 so as todetermine the additional distance by which the indexer 14 advances thecontinuous stock material 12 following the detection of the registrationfeature 104 by the registration monitor 126. Based thereupon, thecontroller can precisely determine the proper position for the spurtrimming station platform 118 during the subsequent trimming operations.

Once the intermittent advance of the continuous stock material 12 hasbeen terminated and the upstream turning head clamp 44 has securelygripped the continuous stock material, the positioner, under control ofthe controller 30, can position the spur trimming station platform 118in a predetermined spaced relationship from the registration feature 104which was identified by the registration monitor 126 during the mostrecent advancement of the continuous stock material, as shown in blocks536-542 of FIG. 55D. In order to facilitate this movement of the spurtrimming station platform, the spur trimming station 116 can include anumber of slides 130 which cooperate with a pair of longitudinallyextending, parallel rails or tracks 132, as shown in FIGS. 35 and 36.

The spur trimming station 116 also includes a pair of opposed spur trimclamps 134 and a pair of opposed spur trim punches 136, all of which aremounted upon the spur trimming station platform 118. Accordingly, oncethe spur trimming station platform has been appropriately positioned,the controller 30 can extend the opposed spur trim clamps so as tosecurely hold the stock material 12 in the desired position, as shown inblock 544 of FIG. 55D. Each of the opposed spur trim clamps preferablyhas a contact surface which substantially matches the predeterminedshape of the part which is being trimmed, such as the blade portion of aspade bit in one advantageous embodiment.

As shown in block 546, the controller 30 can thereafter extend theopposed spur trim punches so as to selectively remove undesirableportions of the continuous stock material 12. In particular, the spurtrim punches are preferably extended past the continuous stock materialso as to remove flash and other undesirable portions of the continuousstock material in the vicinity of the spur. Once these undesirableportions have been removed, the spur of the resulting spade bit is moresharply defined as shown in FIG. 3D. As also illustrated in FIG. 3D,however, the spade bit remains attached to other portions of thecontinuous stock material during the trimming process. Followingextension of the spur trim punches, the controller retracts the spurtrim punches and the spur trim clamps and the trimmed portions areremoved, such as by blowing air or an air/oil mixture thereover for apredetermined period of time, as shown in blocks 548-552. Thereafter,the positioner, operating under control of the controller, canreposition the spur trimming station platform 118 at a predeterminedinitial or rest position.

Concurrent with the trimming of the spur of one spade bit, the formingmethod and apparatus 10 of one advantageous embodiment of the presentinvention also trims the outer diameter of another spade bit. Asdescribed above in conjunction with the spur trimming station 116, theforming method and apparatus of the present invention includes a outerdiameter trimming station 138 through which the continuous stockmaterial 12 extends. According to the present invention, the outerdiameter trimming station includes an outer diameter trimming stationplatform 140 and a positioner for controllably positioning the outerdiameter trimming station platform such that the appropriate portions ofa respective part will be trimmed. While the outer diameter trimmingstation could be positioned in a variety of manners, such as via an ACservomotor and an associated ballscrew, without departing from thespirit and scope of the present invention, the positioner of oneembodiment includes a hydraulic cylinder assembly 142 including acylinder 144 and a piston rod 146 which is operably connected to theouter diameter trimming station platform.

As shown in FIG. 36, the outer diameter trimming station 138 alsopreferably includes a registration monitor 148, such as a photoelectriceye or sensor, which monitors the continuous stock material 12 duringthe intermittent advancement of the continuous stock material by theindexer 14. The registration monitor detects each registration feature104 defined by the continuous stock material as the continuous stockmaterial is advanced. The outer diameter trimming station also includesa position monitor 150, such as an MTS Temposonics® LP position sensingsystem, for monitoring the position of the outer diameter trimmingstation platform 140. As described above in conjunction with the spurtrimming station 116, both monitors are operably connected to thecontroller 30 such that the controller can precisely determine thelocation of the registration feature and the relative position of theouter diameter trimming station platform.

Once the intermittent advance of the continuous stock material 12 hasbeen terminated and the upstream turning head clamp 44 has securelygripped the continuous stock material, the positioner, under control ofthe controller 30, can position the outer diameter trimming stationplatform 140 in a predetermined spaced relationship from theregistration feature 104 which was identified by the registrationmonitor 148 during the most recent advancement of the continuous stockmaterial, as shown in blocks 554-560 of FIG. 55E. In order to facilitatethis movement of the outer diameter trimming station platform, the outerdiameter trimming station 138 can include a number of slides 152 whichride upon and cooperate with a pair of longitudinal extending, parallelrails or tracks 154.

The outer diameter trimming station 138 also includes a pair of opposedouter diameter trim clamps 156 and a pair of opposed outer diameter trimpunches 158, all of which are mounted upon the outer diameter trimmingstation platform 140. Accordingly, once the outer diameter trimmingstation platform has been appropriately positioned, the controller 30can extend the opposed outer diameter trim clamps so as to securely holdthe stock material 12 in the desired position, as shown in block 562 ofFIG. 55E. Each of the opposed outer diameter trim clamps preferably hasa contact surface which substantially matches the predetermined shape ofthe part which is being trimmed, such as the blade portion of a spadebit in one advantageous embodiment.

As shown in block 564, the controller 30 can thereafter extend theopposed outer diameter trim punches 150 so as to selectively removeundesirable portions of the continuous stock material 12. In particular,the outer diameter trim punches are preferably extended past thecontinuous stock material so as to remove flash and other undesirableportions of the continuous stock material along the outer diameter ofthe part. Once these undesirable portions have been removed, the outerdiameter of the resulting spade bit is more sharply defined as shown inFIG. 3E. As also illustrated in FIG. 3E, however, the spade bit remainsattached to other portions of the continuous stock material during thetrimming process. Following extension of the outer diameter trimpunches, the controller retracts the outer diameter trim punches and theouter diameter trim clamps, as shown in blocks 566-570. As shown inFIGS. 35 and 36, air or a mixture of air and oil can be blown over thetrimmed part in order to remove the scrap material once the outerdiameter trim punches and the outer diameter trim clamps have beenretracted.

Downstream of both the spur trimming and outer diameter trimmingstations, the forming apparatus 10 of this embodiment can include a sawstation 160 for separating the continuous stock material 12 intodiscrete parts. As described above in conjunction with the spur trimmingand outer diameter trimming stations and as shown in FIGS. 35 and 36,the saw station preferably includes a saw station platform 161 and anassociated positioner for controllably positioning the saw station suchthat the appropriate portion of the continuous stock material will becut. While the saw station could be positioned in a variety of manners,such as with an AC servomotor and an associated ballscrew, withoutdeparting from the spirit and scope of the present invention, thepositioner of one embodiment includes a hydraulic cylinder assemblyincluding a cylinder 164 and a piston rod 166 which is operablyconnected to the saw station platform.

The saw station 160 also preferably includes a registration monitor 168,such as a photoelectric eye or sensor, for monitoring the continuousstock material 12 during the intermittent advancement of the stockmaterial. The registration monitor detects each registration feature 104defined by the continuous stock material as the continuous stockmaterial is intermittently advanced. The saw station also preferablyincludes a position monitor 170, such as an MTS Temposonics® LP positionsensing system, for monitoring the position of the saw station platform161. As described above in conjunction with the spur trimming station116, both monitors are operably connected to the controller 30 such thatthe controller can precisely determine the location of the registrationfeature and the relative position of the saw station platform.

Once the intermittent advancement of the continuous stock material 12has been terminated and the upstream turning head clamp 44 has securelygripped the continuous stock material, the positioner, under control ofthe controller 30, can position the saw station platform 161 in apredetermined spaced relationship from the most recently identifiedregistration feature 104, as shown in blocks 572-578 of FIG. 55F. Inorder to facilitate movement of the saw station platform, the sawstation 160 can also include a number of slides 172 which ride upon andcooperate with a pair of longitudinally extending, parallel rails ortracks 154.

Referring now to FIGS. 35, 36, 38-40, 43 and 44, the forming apparatus10 of the present invention can also include a size stamp station 176which includes one or more size stamp clamps 178. The size stamp stationalso includes a positioner 181, responsive to the controller 30, forcontrollably positioning the size stamp platform 180. In one embodiment,the positioner includes a stepper motor 183 which is operably connectedto a lead screw 184 for controllably advancing and retracting the leadscrew through a nut assembly 186. Since the nut assembly is alsooperably connected to the size stamp platform, rotational movement ofthe lead screw also moves the size stamp platform. According to oneembodiment, the stepper motor includes a resolver, operably connected tothe controller, for monitoring and controlling the position of the sizestamp platform. However, the positioner can controllably position thesize stamp station according to other techniques without departing fromthe spirit and scope of the present invention.

According to one advantageous embodiment, the saw station 160 and thesize stamp station 176 are initially positioned at their respective homeor rest positions as shown in FIG. 38. After the continuous stockmaterial 12 has been indexed and the saw station has been repositionedbased upon the registration feature as described above, the size stampplatform 180 is advanced by the positioner in an upstream longitudinalposition as shown in FIG. 39. As shown in block 580, the positionerpreferably advances the size stamp platform in an upstream longitudinaldirection until the free or leading end of the continuous stock materialis received within the size stamp clamps 178. In the illustratedembodiment, the size stamp platform is advanced in an upstreamlongitudinal direction until the blade portion of the leading spade bitis received within the size stamp clamps.

As shown in FIG. 41, each size stamp clamp 178 includes a size stamp dieassembly comprised of a die assembly which includes an alignment fixture190, such as a spider, and a plurality of size stamp dies 188 which areheld within the alignment fixture. The size stamp clamp can also includea closure 192 which is adapted to receive the size stamp die assembly.The size stamp station 176 can also include means, such as a hydrauliccylinder assembly 194 which operates under control of the controller 30,for urging the closure over the size stamp die assembly such that thesize stamp dies are closed about the leading end of the continuous stockmaterial as shown in block 582 of FIG. 55F.

The size stamp dies 188 preferably have a shape which matches the shapeof the part to be held by the size stamp clamp 178, such as the shape ofthe blade portion 418 of a spade bit 410. The size stamp dies alsopreferably include one or more raised numerals for imprinting the sizeof the respective spade bit upon the blade portion thereof. While sizestamp dies are illustrated which are adapted to imprint the size of therespective part upon the part thereon, the size stamp dies need onlyserve as a clamp for holding or gripping the leading end of thecontinuous stock material 12. Thus, the size stamp dies may have a shapewhich matches the shape of the part to be held, but need not include theraised numerals described above.

While the blade portion 418 of the spade bit 410 is held by the sizestamp clamp 178, the controller 30 can advance the saw 198 toward thecontinuous stock material 12 so as to cut through the continuous stockmaterial at a location proximate the forward end of the spade bit, i.e.,at a location proximate the spur tip, as designated A in FIGS. 39 and42. As shown in dashed lines in FIG. 37, the saw is rotatably advancedso as to cut through the continuous stock material, thereby separatingthe leading part from the remainder of the continuous stock material, asshown in FIG. 3F and in block 584 of FIG. 55F. The saw station 160 canalso include a proximity sensor, operably connected to the controller,for detecting the advancement of the saw to a predetermined position.Thereafter, the controller can retract the saw to its initial positionas shown in solid lines in FIG. 37.

Once the continuous stock material 12 has been cut and the controller 30has retracted the saw 198, the positioner of the saw station 160, undercontrol of the controller, moves the saw station in a downstreamdirection as shown in FIG. 40 and block 585 of FIG. 55F until the saw isaligned with the chamfered edge 112 on the rearmost portion of the shank412 of the spade bit 410. The saw is then rotatably advanced once againto cut through the continuous stock material at a location proximate therear of the spade-type boring bit designated B in FIGS. 40 and 42. Seealso FIG. 3G and block 586 of FIG. 55F. As a result of the cuts made atlocations designated A and B in the illustrated embodiment, theconnector 200 is also separated from the continuous stock material andfrom the leading part. Upon indexing the continuous stock material, thepiece of scrap will be discharged from the saw station and can bedirected through a chute 187 to a bin or the like, as indicated in FIG.39.

Thereafter, the positioner of the size stamp station 176, under controlof the controller 30, moves the size stamp platform 180 in a downstreamdirection as shown in FIG. 43 and in block 587 of FIG. 55F. Preferably,the size stamp station platform is moved in a downstream longitudinaldirection by a linear distance which exceeds the longitudinal growth ofthe continuous stock material 12 in the downstream longitudinaldirection during one sequence of forming operations. For example, thesize stamp station can be moved in a downstream longitudinal directionby the expected amount of longitudinal growth of the continuous stockmaterial in the downstream direction plus a predetermined additionalamount, such as 0.100 inch. As shown in FIG. 38, the size stamp platformcan be moved from an upstream position as depicted in dashed lines to adownstream position as depicted in solid lines.

Accordingly, additional portions of the continuous stock material 12 cannow be forged without contacting the discrete part held by the sizestamp clamp 178. Thus, the forming method and apparatus 10 of thepresent invention can continue to process the discrete part held by thesize stamp clamp while forming additional portions of the continuousstock material at the same time. Once the size stamp station 176 hascompleted stamping operations, the size stamp station can eject thestamped part which may be directed by means of a chute 189, conveyor orthe like to a bin as shown in FIGS. 43 and 44 and in block 589 of FIG.55F. Although the size stamp station can eject the stamped part in avariety of manners, the size stamp station of the illustrated embodimentincludes a kicker rod 191 which can be spring extended so as to ejectthe stamped part once the size stamp dies 188 have been opened.

As shown in FIGS. 45 and 46, the forming method and apparatus 10 of thepresent invention need not include separate stations for trimming theoutside diameter of the resulting part and for sawing or otherwiseseparating the resulting part from the remainder of the continuous stockmaterial 12. Instead, the forming method and apparatus of anotherembodiment of the present invention include a trimmer, such as anoutside diameter trimming station 138, and a separator, such as asnipping station 400, mounted upon a common platform 402 so as to movetogether in a longitudinal direction. As shown in FIGS. 45 and 46, forexample, the outside diameter trimming station and a snipping stationcan be mounted upon a common platform. The platform can include aplurality of slides 152 mounted upon a pair of longitudinal extendingrails 406 such that the platform which carries the outside diametertrimming station and the snipping station can be moved longitudinally.

The combined trimming and separating station includes a hydraulicactuator including a cylinder 415 and a piston rod 417 for appropriatelyspacing the outer diameter trimming station 138 and the snipping station400. In this regard, the snipping station preferably includes a movableplatform 401 mounted upon a support platform 402 and adapted to be movedin a longitudinal direction relative to the support platform and, moreparticularly, relative to the outer diameter trimming station. Basedupon the predetermined spacing and size of the parts, the controller 30can direct the hydraulic actuator to position the movable platform suchthat a leading port can be snipped, while a trailing part is trimmed. Asshown in FIG. 45, the combined trimming and snipping station can includea support 402 a, such as a hydraulic spring, for supporting thecantilevered snipping station.

As described above in conjunction with the outside diameter trimmingstation 138, the combined trimming and snipping station also includes apositioner for controllably positioning the platform 402 such that theappropriate portions of the respective part will be trimmed and snipped.While the platform could be positioned in a variety of manners, such asvia an AC servomotor and an associated ball screw, without departingfrom the spirit and scope of the present invention, the positioner ofone embodiment includes a hydraulic cylinder assembly including acylinder 408 and a piston rod 409 which is operably connected to theplatform. The combined trimming and snipper station also preferablyinclude a registration monitor 148, such as a photoelectric eye orsensor, which monitors the continuous stock material 12 during theintermittent advancement of the continuous stock material by the indexer14. As described above, the registration monitor detects eachregistration feature 104 defined by the continuous stock material as thecontinuous stock material is advanced. The combined trimming and snipperstation also includes a position monitor 405, such as an MTSTemposonics® LP position sensing system, for monitoring the position ofthe platform. As also described above, both the registration monitor andthe position monitor are operably connected to the controller 30 suchthat the controller can precisely determine the location of theregistration feature and the relative position of the platform and, inturn, the relative positions of the outside diameter trimming station138 and the snipping station 400 carried by the platform.

Once the intermittent advance of the continuous stock material 12 hasbeen terminated and the upstream turning head clamp 44 has securelygripped the continuous stock material, the positioner, under control ofthe controller 30 can position the platform 402 in a predeterminedspaced relationship to the registration feature 104 which is identifiedby the registration monitor 148 during the most recent advancement ofthe continuous stock material. As described above, the controller canthen extend the opposed outer diameter trim clamps 156 so as to securelyhold the stock material in the desired position while the opposed outerdiameter trim punches 158 are thereafter extended so as to selectivelyremove undesirable portions of the continuous stock material. Followingextension of the outer diameter trim punches, the controller retractsthe outer diameter trim punches and the outer diameter trim clamps.

While the outside diameter trimming station 138 trims one part, thesnipping station 400 preferably snips another part since the controller30 has already properly spaced the outside diameter trimming station andthe snipping station based upon the spacing and the size of the parts.As shown in FIG. 45, the snipping station includes a pair of snip dies422 having a pair of cutting edges that are longitudinally spaced apart.The controller 30 can therefore extend the pair of snip dies whichseparate the continuous stock material 12 at the locations designated Cand D in FIG. 47. In the illustrated embodiment in which the formingmethod and apparatus 10 forms a plurality of spade-type boring bits 410,the snipping station 400 can be configured to separate or snip thecontinuous stock material at a location designated C proximate theforward end of the spade bit, i.e., proximate the spur tip, and at alocation designated D proximate the chamfered edge 112 on the rearmostportion of the shank 412 of the spade bit to thereby create scrap 200 a.Once the continuous stock material has been separated at the locationsdesignated C and D, the controller retracts the snip dies to permitfurther indexing of the continuous stock material.

By mounting the outside diameter trimming station 138 and the snippingstation 400 on a single platform 402, the forming method and apparatus10 of this embodiment is simplified since only a single positioner, asingle registration monitor 148 and a single position monitor 405 arerequired for precise movement and alignment of the outside diametertrimming and snipping station. In addition, by utilizing the snippingstation, the continuous stock material can be simultaneously separatedat two different locations designated C and D without having toseparately reposition the saw or cutter at each of the locations asdescribed above. However, the snipping station can include means otherthan snip dies, such as a pair of saw blades or the like, forsimultaneously cutting the continuous stock material at two spaced apartlocations, i.e., at locations designated C and D.

Prior to separating the leading part from the continuous stock material12, the free end of the leading part is preferably grasped by the sizestamp clamps 178 of a size stamp station 176. In this regard, the sizestamp station also includes a positioner 181, responsive to thecontroller 30, for controllably positioning the size stamp platform 180.In one embodiment, the positioner includes a stepper motor 183 which isoperably connected to a lead screw 184 for controllably advancing andretracting a lead screw through a fixed nut 186. Since the nut assemblyis also operably connected to the size stamp platform, rotation of thelead screw also moves the size stamp platform. As will be apparent,however, the positioner can controllably position the size stamp stationaccording to other techniques without departing from the spirit andscope of the present invention.

Once the continuous stock material 12 has been appropriately indexed,the controller directs the positioner 181 to advance the size stampstation 176 in an upstream direction such that the free end of theleading part is received within the size stamp clamps 178. In theillustrated embodiment, the size stamp platform 180 is advanced in anupstream longitudinal direction until the blade portion of the leadingspade bit is received within the size stamp clamps.

As described above, each size stamp clamp 178 generally includes a sizestamp die assembly which includes an alignment fixture, such as aspider, and a plurality of size stamp dies which are held within thealignment fixture. By closing the size stamp die about the free end ofthe continuous stock material, the size stamp die can stamp the free endof the continuous stock material with the size of the respective part asalso described above.

Once the snipping station 400 has separated the leading part from theremainder of the continuous stock material 12 and the snipping dies 422have been retracted, the positioner 181 can move the size stamp station176 in a downstream longitudinal direction. In the illustratedembodiment, the size stamp platform 180 is mounted upon a turret adaptedfor rotational motion. While the size stamp platform can be rotated in avariety of manners, the size stamp platform of one embodiment includes arotary actuator 650, such as shown in FIG. 48. As will be apparent tothose skilled in the art, the rotary actuator includes a dual endedcylinder 652 a,652 b that can be pneumatically actuated in order to movea rack relative to a pinion gear 654 a which, in turn, rotates theupstanding post 654 upon which the size stamp platform is mounted. Assuch, the controller 30 preferably not only directs the positioner tomove the size stamp station in a downstream longitudinal direction, butalso directs that the rotary actuator be pneumatically actuated so as torotate the size stamp platform through a predetermined angle, such asthrough about 180° in the typical embodiment.

The forming apparatus 10 of this embodiment also includes a saw station656 disposed downstream of the size stamp station 176 for cutting theresulting part to length. In the illustrated embodiment in whichspade-type boring bits 410 are fabricated, the controller 30 preferablyrotates and longitudinally advances the size stamp platform in adownstream longitudinal direction until the saw blade 657 is alignedwith the chamfered edge 112 on the rearmost portion of the shank 412 ofthe spade bit. The controller then halts further movement of the sizestamp platform and actuates the saw station.

As shown in FIGS. 49 and 50, the saw station 656 is adapted to move in adirection generally perpendicular to the continuous stock material 12.In this regard, the saw station 656 generally includes a pair of slides662 which ride upon a rail 659 mounted to a fixed platform 660. Inaddition, the saw station includes a positioner, such as a hydraulic orpneumatic actuator 658, for moving a saw mounting bracket 663 whichholds the saw, including the saw blade 657, such that the saw blade canalso be moved toward and away from the continuous stock material.Finally, the saw station can include a saw clamp 664 for holding thecontinuous stock material during sawing operations to prevent movementof the stock material. Thus, once the size stamp platform 176 hasappropriately aligned the part with the saw blade 657 and the saw clamphas engaged the continuous stock material, the controller 30 can directthe positioner to laterally advance the saw platform such that the sawcuts through the continuous stock material at the desired location tocreate scrap 200 b that falls upon and is removed via conveyor 667 oncethe saw clamp is opened. Thereafter, the saw can be retracted. As such,the rearmost portion of the spade-type boring bit 410 can be formed bycutting the spade-type boring bit at a location designated E in FIG. 47.Following cutting operations, the size stamp station opens the sizestamp clamps 178 such that the resulting part, such as the resultingspade bit, is released from the size stamp clamp and falls into a chute665, a conveyor or the like for collection in a bin for subsequentprocessing. As described above, the size stamp station can also includea spring actuated kicker rod for ejecting the resulting part followingthe sizing operations, if so desired.

Although the forging method and apparatus 10 has been describedhereinabove to include a single indexer 14 disposed upstream of theforge 50 for pushing the continuous stock material 12 along thepredetermined path, the forming method and apparatus can also include adownstream indexer for intermittently pulling the continuous stockmaterial in the downstream direction. In contrast to the upstreamindexer, the downstream indexer is disposed downstream of the forge.However, the upstream and downstream indexers are synchronized in thisembodiment so as to work together to longitudinally advance thecontinuous stock material in the downstream direction along thepredetermined path. In this regard, the upstream and downstream indexersare preferably synchronized such that the upstream and downstreamindexers concurrently push and pull the continuous stock material in thedownstream direction. In addition, the upstream and downstream indexersare also preferably synchronized so as to intermittently push and pullthe continuous stock material by the same predetermined-distance in thedownstream direction.

Although the downstream indexer can be constructed to be the same orsimilar as the upstream indexer 14 described hereinabove, the formingmethod and apparatus 10 of one advantageous embodiment utilizes the spurtrimming station 116, the outer diameter trimming station 138 or bothstations as the downstream indexer. In this regard, the controller 30preferably indexes continuous stock material by directing not only theindexer clamp 16, but also the spur trim clamps 134 and/or the outerdiameter trim clamps 156 to be extended and grip the continuous stockmaterial. In order to grip the appropriate portions of the continuousstock material, the controller must have previously repositioned theindexer, the spur trimming station and the outer diameter trimmingstation to their respective upstream home positions prior to engagingthe continuous stock material. Once the continuous stock material hasbeen engaged, the controller of this embodiment preferably directs thepositioners of the indexer, the spur trimming station and the outerdiameter trimming station to simultaneously move the indexer, the spurtrimming station and the outside diameter trimming station in adownstream direction at the same rate for the same predetermineddistance. As such, the forming method and apparatus of this advantageousembodiment will concurrently push and pull the continuous stock materialalong the predetermined path and, in the illustrated embodiment, throughthe forges. By both pulling and pushing the continuous stock material,the continuous stock material will be less likely to be bent, kinked, orotherwise damaged during the indexing process. Once the continuous stockmaterial has been indexed by the predetermined distance, the controllerdirects the indexer clamp, the spur trim clamps and the outer diametertrim clamps to release the continuous stock material such that theforming operations can proceed as described above.

As mentioned above, the forming apparatus 10 of the present inventioncan include one or more additional forges, such as a second forge 204for forming another portion of the continuous stock material 12 into asecond predetermined shape, as shown in detail in FIGS. 20, 24 and 27.Thus, the parts formed by the forming method and apparatus of thepresent invention can include both the first and second shapes impartedby the first and second forges, respectively, at different stages alongthe forming process. As described above in conjunction with the hexforge 50, the second forge of one advantageous embodiment preferablyincludes a blade press forge for forming the blade portion of theresulting spade bits as shown in FIG. 3C. However, the second forge canbe adapted to form a variety of different features on one or moreportions of other types of parts without departing from the spirit andscope of the present invention.

Although the use of both upstream and downstream indexers serves toreduce the possibility that the continuous stock material 12 will bekinked, the forming method and apparatus 10 can include an alignmentdetector 465 disposed upstream of the second forge 204. As shown in FIG.21, the alignment detector can include a forked member 466 having a pairof tongs 467 between which the continuous stock material passes. If thecontinuous stock material is kinked or otherwise bent, the continuousstock material will contact one of the tongs and cause the forked memberto rotate about a pivot point 468. As such, the rotation of the forkedmember will take the forked member out of contact with a contact sensor469 which will report the kinked or bent stock material to thecontroller 30. As such, the controller can halt further formingoperations until the continuous stock material has been straightened,thereby preventing the manufacture of imprecise parts and the possibledamage to downstream equipment. Although one embodiment of the alignmentsensor is illustrated and has been described hereinabove, the alignmentsensor can be embodied in many different manners without departing fromthe spirit and scope of the present invention.

As also described above in conjunction with hex forge 50 and as shown inFIGS. 20, 24 and 27-31, the blade press forge 204 preferably includes apair of opposed forging dies 206 which cooperate to define a cavityhaving a predetermined shape. The cavity, in turn, defines the shape ofat least a portion of the resulting part, such as the blade portion ofthe resulting spade bit. With respect to the illustrated embodiment ofthe forming method and apparatus 10 which is adapted to form spade bits,at least one, and, more preferably, each forging die can include acontact surface 208 of a somewhat Z-shaped configuration which defines aportion of the cavity.

As shown in FIGS. 28 and 29, the Z-shaped cavity includes a centralportion 210 defining a central plane and opposed side portions or wings212 extending from opposite sides of the central portion. The opposedside portions define respective lateral planes which are oblique to thecentral plane. The respective contact surfaces 208 of the opposedforging dies 206 contact and shape the workpiece into the predeterminedshape of a portion of the resulting part.

The contact surface 208 of at least one forging die 206 defines at leastone contact plane which, according to one embodiment, is oblique to thepredetermined direction in which the forging dies are closed. Forexample, as shown in FIGS. 28 and 29, the center portions 210 of therespective contact surfaces are oblique to the predetermined directionin which the forging dies are closed and define respective contactplanes. More particularly, an angle is defined between the respectivecontact planes and a reference plane perpendicular to the predetermineddirection in which the forging dies move as shown in FIG. 29. In apreferred embodiment, the angle is between about 10° and about 20° and,in one specific example, is about 15°.

As a result of the oblique orientation of the respective contact planesto the predetermined direction in which the forging dies 206 are closed,the contact planes of the forging dies impart both axial and radialforces to the workpiece which, in turn, result in compressive, tensileand shear stresses within the workpiece during the deformation process.The resulting compressive, tensile and shear force components deform theworkpiece outwardly into the predetermined shape defined by the forgingdies.

As described above, the application of shear forces to deform aworkpiece significantly increases the forces which the forging dies 206and a surrounding ram 217 must withstand during the forging process. Inorder to withstand the increased forces, the opposed forging dies andthe ram are comprised, in one preferred embodiment, of a high speedsteel and, more preferably, are comprised of CPM® REX™ M4 high speedsteel, or an equivalent, marketed by Colt Industries Crucible SpecialtyMetals Division of Syracuse, N.Y.

In addition, the energy required to deform a workpiece with shear forcesis generally less than the corresponding energy required to deform asimilar workpiece with compressive forces. However, for parts which havea relatively small diameter, such as spade bits having a diameter ofabout ⅜ inch or less, in which deformation of the workpiece with shearforces will not conserve a significant amount of input energy, the angle214 defined between the respective contact planes and the referenceplane 216 is decreased, or eliminated, such that increasing amounts ofcompressive force are imparted to the workpiece and the deformationprocess proceeds effectively, particularly since the working stroke isgenerally reduced. In these embodiments, however, shear forces can stillbe imparted, albeit in lesser amounts, by the contact surfaces whichinclude oblique lateral portions such as illustrated by the Z-shapedcavity of FIGS. 28 and 29. For parts with a relatively large diameter,such as spade bits having a diameter of about {fraction (7/16)} inch orgreater, in which deformation of the workpiece with shear force willconserve a significant amount of input energy, the respective contactplanes are preferably disposed at an angle, such as 15°, for example,with respect to the reference plane.

According to one aspect of the present invention, the back surface 478of the forging dies 206 have also been redesigned to ensure that forcesare applied more evenly across the back surface of the die, therebydecreasing the wear of the dies and correspondingly increasing theexpected life of the forging dies. In this regard, the back surface ofthe forging dies includes a medial section 480 and first and secondlateral sections 482 disposed in opposite sides of the medial section.As shown in FIG. 30, the medial section has a partial conical shape. Inone embodiment, for example, the medial section has a surface defined bya portion of a cone having an included angle of about 30°. Likewise,each lateral section has a partial conical shape. According to thepresent invention, however, the radius R_(m) defined by the conicalmedial section is larger than the radius R_(L) defined by the conicallateral section at each corresponding location along the length of theforging die. As a result, the first and second lateral sections arerecessed relative to the medial section such that forces will beprincipally applied to the medial section of the back surface in orderto urge the forging die into contact with the workpiece. In contrast toprior forging dies in which the forces were applied to a limited area,such as along a line of contact, the forging die of this aspect of thepresent invention permits forces to be applied across a much widerregion, namely, across virtually the entire medial section. By applyingthe forces across a wider area, the forging die should be forcedradially inward in a more even manner and the expected wear on the dieshould be decreased, thereby increasing the anticipated life of theforging die.

As shown in FIG. 30, the forging die 206 is preferably tapered. In thisregard, the height of the forging die as defined between the contactsurface 208 and the back surface 478 is preferably greater at a firstend 206 a of the forging die than at an opposed second end 206 b of theforging die. As a result of the tapered shape of the forging die, themedial section is also tapered. In this regard, the width of thecylindrical medial section is generally greater adjacent the first endof the forging die and is smaller at the second end of the forging die.Thus, the surface of the medial section generally has a trapezoidalshape.

The blade press forge 204 also preferably includes an alignment fixture220, such as a spider, for maintaining the pair of opposed forging dies206 in a predetermined aligned relationship during the forging process.The alignment fixture and the pair of opposed forging dies comprise adie assembly which, in one preferred embodiment, is frustoconical inshape.

The blade press forge 204 further includes means, such as a ram 217, forradially closing the opposed forging dies 206. Although the ram can beformed of three or more components as illustrated and described by the'267 patent, the ram can also be formed of two components as shown inFIGS. 24 and 27 or the ram can be integrally formed, as describedhereinbelow. In these embodiments, the ram can be constructed to havegreater amounts of preload, that is, to have greater hoop stress, inorder to reduce flexure of the ram during forging operations. In eitherembodiment, the ram 217 defines a die cavity opening through the forwardend of the ram and having a shape, such as a frustoconical shape, whichis complimentary to the shape of the die assembly. Like the ramdescribed above in conjunction with the hex forge 50, the ram of bladepress forge 204 includes a die housing. As shown in FIGS. 24 and 27, theram can be constructed such that the inner sidewalls which define thedie cavity serve as the die housing. Alternatively, the ram can includea separate annular component which is press fit into the die cavity asdescribed above in conjunction with the hex forge.

In the embodiment illustrated in FIGS. 20, 24 and 27, the blade pressforge 204 also includes a head 218 defining a passageway which extendslengthwise through at least a forward portion of the head. As describedabove in conjunction with the hex forge 50, the size and shape of thepassageway defined by the head preferably corresponds to the size andshape of the forward portion of the ram 217. For example, the ram andthe passageway defined by the head are generally cylindrical. Inaddition, at least portions of the ram and the passageway defined by thehead are sized such that the ram is interference fit within thepassageway defined by the head.

In contrast to prior designs which provided an interference fit betweenthe ram 217 and the entire length of the passageway defined by the head218, the interior surface of the head and the exterior surface of theram of one advantageous embodiment cooperate to define a clearanceregion proximate the forward end of the ram. The clearance regionpermits the forward end of the ram to slightly deflect in a radiallyoutward direction as the ram is advanced and the die assembly isinserted further into the die cavity. In other words, the clearanceregion defines a larger gap between the head and the forward portion ofthe ram than between the head and other more rearward portions of theram, such as those portions of the ram which are interference fit withinthe head. By permitting a slight radially outward deflection of theforward portion of the ram, the blade press forge 204 of thisadvantageous embodiment can accommodate the anticipated flexure of theram without imposing significant forces upon the ram and the head whichmay shorten the effective lifetime of those components. By maintainingan interference fit between other portions of the ram and the head,however, the forge of this advantageous embodiment still maintains theprecise alignment and guidance required between the ram and the dieassembly.

In designing the ram 217 and the head 218 of the embodiment illustratedin FIG. 27, the ram was divided into three zones, namely, a forward loadzone, a medial neutral zone and a rear no load zone. As indicated by theterminology, the forward load section of the ram is that portion of theram which experiences significant loads as the ram is longitudinallyadvanced and the die assembly is inserted into the die cavity. Incontrast, the rearward no load section of that portion of the ram whichexperiences little, if any, loading as the ram is longitudinallyadvanced and the die assembly is inserted further into the die cavity,while the medial neutral section is a transition region. Accordingly,the length of the clearance region is approximately equal to the widthof the forward load section. Stated differently, the width of theclearance region preferably extends from a location proximate theforward end of the ram to a location at least as rearward as therearwardmost location to which the forging dies are inserted into thedie cavity once the ram has been completely longitudinally advanced.Thus, the clearance region will permit slight radially outward flexureof that portion of the ram which surrounds the die assembly followingthe longitudinal advancement of the ram during forging operations.

In the illustrated embodiment, the head 218 defines a circumferentialgroove 438 proximate the forward end of the ram 217 which serves as theclearance region. Alternatively, the ram could define a circumferentialgroove to serve as the clearance region. Still further, both the ram andthe head could define aligned grooves which cooperate to serve as theclearance region. In any event, the depth of the groove should be atleast as great as the anticipated radial outward flexure of the forwardportion of the die, such as 0.0175 inch in one embodiment.

In order to ensure that the ram 217 is properly guided within thepassageway defined by the head 218, the rearward no load portion of theram is preferably interference fit within the head such that the ramwill be properly aligned with the die assembly as the ram islongitudinally advanced and retracted. In addition, the head can includea bronze bushing 440 which is sized to create an interference fit with arear portion of the ram. See FIGS. 24 and 27. As known to those skilledin the art, a bronze bushing will conform to the shape of the ram inorder to further align the ram within the passageway defined by thehead.

As shown in FIGS. 51 and 52, the forge 442 of another embodiment doesnot include a head 218. Instead, the forge includes a ram 444constructed to have a much thicker wall than the ram of the embodimentdepicted in FIGS. 24 and 27. As such, the ram of FIGS. 51 and 52 canwithstand the forces created as the ram is longitudinally advanced andthe die assembly 446 is further inserted into the die cavity defined bythe ram. As described above in conjunction with other embodiments, theram of this embodiment is preferably formed of a high speed steel, suchas CPM® REX™ M4 high speed steel, or an equivalent, marketed by ColtIndustries Crucibles Specialty Metals Division of Syracuse, N.Y.

In order to facilitate alignment of the ram 444 with the die assembly446 as well as to facilitate longitudinal advancement and retraction ofthe ram during forging operations, the forge 442 of this embodiment canalso include a ram support platform 450. As shown in FIGS. 51 and 52 theram support platform includes a plurality of slides 451 mounted uponlengthwise extending rails 452 to permit the ram support platform tomove longitudinally with the ram. The ram support platform is mountedbeneath the ram so as to support the ram prior to, during and followingthe forging operations.

The ram support platform 450 also includes means for adjusting theheight of the ram 444 relative to the remainder of the forge 442,including the die assembly 446. While the ram support platform caninclude various means for adjusting the height of the ram, the ramsupport platform of the illustrated embodiment includes a pair oflengthwise extending rollers 454 which extend lengthwise along opposedsides of the ram for aligning and supporting the ram. In order to moredefinitively position the rollers relative to the ram, the exteriorsurface of the ram of the illustrated embodiment preferably defines acircumferentially extending groove 456 sized to receive the rollers.

By controllably adjusting the spacing between the rollers 454, the ram444 can be raised and lowered. In particular, the ram can be raised bydecreasing the spacing between the rollers or lowered by increasing thespacing between the rollers. As shown in FIGS. 53 and 54, the ramsupport platform 450 of one embodiment includes a base plate 458 whichextends between a pair of slides 451 which ride upon each of thelengthwise extending rails 452. As shown most clearly in FIG. 53, theram support platform of this embodiment also includes a pair of brackets460 which carry respective rollers and are mounted upon opposite sidesof the base plate. As such, the ram can be positioned upon the ramsupport platform such that the rollers seat within the circumferentialgroove 456 defined by the exterior surface of the ram.

As shown in FIGS. 53 and 54, the ram support platform 450 of thisembodiment also includes a threaded member 462 associated with eachbracket 460. The threaded member is threadably connected to the baseplate 458 such that the threaded member can be threadably advanced andretracted relative to the base plate. In contrast, the bracket iscarried by a medial portion of the respective threaded member so as tomove inward and outward relative to the ram 444 as the threaded memberis threadably advanced into the base plate and threadably retracted fromthe base plate, respectively. Although the bracket can be carried by thethreaded member in a variety of manners, the bracket of the illustratedembodiment includes a bushing 464 through which the threaded memberextends and which is adapted for movement therewith. As such, thethreaded members can be rotated in order to move the rollers closertogether so as to raise the ram or to move the rollers further apart soas to lower the ram. As such, the ram can be precisely aligned with thedie assembly prior to commencing forging operations and can thereafterbe supported during forging operations by the die support platform ofthe present invention.

As shown in FIGS. 20 and 24, the blade press forge 204 of one embodimentcan also include adjustable supports 470 which support and align thehead 218, and, in particular, the front and rear plates 218 a, 218 b. Asshown in more detail in FIGS. 22 and 23, each support includes a pair ofslides 472 which are mounted upon respective lengthwise extending rails235 for facilitating longitudinal movement of the adjustable support aswell as the head supported by the adjustable supports. The pair ofslides is generally connected by a support member 474 which extendsbetween the slides and which underlies and supports the respective headframe. Each adjustable support also include an adjustment mechanism 476,such as a threaded adjustment member, which can be threadably advancedand retracted in order to correspondingly raise and lower the respectiveframe of the head. As such, the head can be appropriately aligned withrespect to the other components of the forge, such as the ram 217 andthe die assembly during the initial configuration of the forge. Inaddition, the adjustable supports serve to support the head and othercomponents of the forge during forging operations, thereby protectingthe head and other components of the forge from slowly being drawndownwardly by the force of gravity.

As shown in FIGS. 20 and 24, the blade press forge 204 preferablyincludes a blade press 224 for urging the ram 217 over the die assembly.As shown, the blade press can include an annular cylinder 226 and anannular piston rod 228 which is at least partially disposed within thecylinder and through which the continuous stock material extends. Oneend of the annular piston rod is also operably connected to the ram suchthat movement of the annular piston rod also moves the ram.

As shown in FIGS. 20 and 24, the blade press forge 204 includes a frameplate 230, connected to the rear head plate 218 b by means of tie rods218 c, and an associated wear plate against which the opposed forgingdies 206 are butted, thereby preventing longitudinal advancement of theforging dies. Thus, the controller 30 can extend the annular piston rod228, such as by hydraulically actuating the blade press 224, to urge theram 217 over the die assembly, thereby closing the pair of opposedforging dies about a portion of the continuous stock material 12. Whilean annular cylinder 226 and an annular piston rod are illustrated anddescribed, the blade press can also include other means for moving thedie housing relative to the pair of opposed forging dies, such as aplurality of hydraulic cylinder assemblies which are in operativecontact with the die housing and which are concentrically disposed aboutthe continuous stock material. Further, while the pressure or forcerequired to urge or axially displace the die housing over the dieassembly will vary depending upon the processing conditions, includingthe type of material from which the workpiece is formed and the size andshape of the resulting part, a hydraulic blade press, such as a 500 tonpress, has produced spade bits of the present invention from 1050 carbonsteel.

In order to form parts of the desired shape and size, the blade pressforge 204 press preferably acts upon or forges only a predeterminedportion of the continuous stock material 12. In particular, the bladepress forge preferably only deforms a portion of the continuous stockmaterial which is spaced by a predetermined longitudinal distance from arespective registration feature 104. Thus, the blade press forge and thecontinuous stock material must be precisely aligned to insure that theblade press forge deforms the proper portion of the continuous stockmaterial. Preferably, the first and second forges, namely, the hex forge50 and the blade press forge in the exemplary embodiment, both forgeportions of the same part, albeit at different stages in the fabricationprocess. Thus, each part can have both the first and secondpredetermined shapes imparted by the first and second forges,respectively.

As described above in conjunction with the hex forge 50, the blade pressforge 204 preferably includes a carriage 232 on which the blade press224, the ram 217, the head 218, the pair of opposing forging dies 206and the frame plate 230 are mounted. The blade press carriage ispreferably adapted for controlled longitudinal movement. As such, theblade press forge can include one or more slides 233 which ride upon andcooperate with longitudinally extending, parallel rails or tracks 235.In addition, the blade press preferably includes a positioner, such as ahydraulic cylinder assembly 224 including a hydraulic cylinder 226 and apiston rod 228, disposed in operable contact with the blade presscarriage and responsive to the controller 30 such that the controllercan controllably position the blade press carriage by hydraulicallyactuating the hydraulic cylinder assembly.

As shown in FIG. 20A, the blade press forge 204 also preferably includesa blade press carriage position sensor 240, such as MTS Temposonics® LPposition sensing system, for monitoring the relative position of theblade press carriage 232. As such, the position sensor provides thecontroller 30 with signals indicative of the relative position of theblade press carriage.

Referring now to FIG. 27, the blade press forge 204 of the presentinvention also preferably includes a registration monitor 242, such as aphotoelectric eye or sensor, which monitors the continuous stockmaterial 12 during the intermittent advancement of the continuous stockmaterial by the indexer 14. The registration monitor detects eachregistration feature defined by the continuous stock material as thecontinuous stock material advances. As described above in conjunctionwith the spur trimming station 116, the controller 30 is preferablyoperably connected to the registration monitor and the position sensorssuch that the controller can controllably position the blade presscarriage 232 based upon the relative position of the blade presscarriage and the location of the registration feature such that the pairof opposed forging dies 206 contact a portion of the continuous stockmaterial which is disposed in a predetermined spaced relationship fromthe registration feature identified during the most recent advance ofthe continuous stock material. See blocks 588-594 of FIG. 55G. While theblade press carriage can be positioned in a variety of differentmanners, the blade press forge of one embodiment includes a hydrauliccylinder 268 attached to the frame plate 230 and adapted to position theframe plate relative to a fixed point defined by the end of a threadedrod 280 which threadably engages a fixed nut assembly 282 mounted to theunderlying platform 484

Once the blade press carriage 232 has been properly positioned, aportion of the continuous stock material 12 upstream of the forging dies206 is securely gripped, as shown in block 596. In particular, the bladepress forge 204 preferably includes an upstream clamp 244 for securelygripping a portion of the continuous stock material which, in oneembodiment, will eventually be a medial portion of the shank 412 of theresulting spade bit 410. As described above in conjunction with otherclamps and as shown in FIG. 27, the upstream clamp preferably includesan annular collet 246 through which the continuous stock materialextends. The upstream clamp also preferably includes an annular closure248 and a hydraulic cylinder assembly 250, operating under control ofthe controller 30, for urging the annular closure over the annularcollet such that the collet is closed about and securely grips thecontinuous stock material extending therethrough.

Thereafter, a portion of the continuous stock material 12 downstream ofthe forging dies 206 is securely gripped. In particular, the blade pressforge 204 also preferably includes a downstream clamp 252 for securelygripping a portion of the continuous stock material downstream of theforging dies as shown in block 598. In particular, the downstream clamppreferably grips the connector 200 which extends between and joins apair of adjacent parts, such as a pair of adjacent spade bits.

While the downstream clamp 252 can be configured in a variety of mannerswithout departing from the spirit and scope of the present invention,the downstream clamp of one advantageous embodiment is shown in FIG. 32and includes a pair of dies 254 disposed within a respective alignmentfixture 256. The alignment fixture, in turn, is mounted to and extendsoutwardly in an upstream longitudinal direction from a clamp plate 258as illustrated in FIG. 27. As shown in FIGS. 27 and 32, the clamp plateincludes a cam sleeve 259 which receives the alignment fixture and whichdefines a pair of opposed pockets 260 which are adapted to receive outerportions of the dies. As also shown in FIG. 32, the outer portions ofthe dies which are disposed within respective pockets preferably includea respective outer cam surface 262. Thus, upon rotation of the camsleeve relative to the alignment fixture and the dies, the outer camsurfaces of the dies and the pockets defined by the cam sleeve willcooperate to force the dies inward toward the continuous stock material12 so as to securely grip the continuous stock material therebetween.

As shown in FIGS. 27, 33 and 34, the blade press forge 204 can include alever arm 264 which is operably connected to both the alignment fixture256 and the controller 30. Accordingly, the controller can rotate thelever arm by a predetermined amount, such as by hydraulic actuation ofan associated hydraulic cylinder assembly 266. By rotating the leverarm, the alignment fixture is correspondingly rotated relative to theclamp plate 258. The blade press forge can also include a proximitysensor, operably connected to the controller, for detecting that thelever arm has been rotated by the predetermined amount. Alternatively,the blade press forge can include a pressure switch, operably connectedto the hydraulic cylinder assembly and the controller, for detecting thehydraulic pressure supplied to rotate the lever arm. In either instance,the controller can then halt further rotation of the lever arm upon thedetection of sufficient rotation of the lever arm or of a sufficientsupply of hydraulic pressure since the downstream clamp 252 shouldalready be securely gripping the continuous stock material 12.

Once the upstream and downstream clamps have been closed about thecontinuous stock material 12, the blade press 224 preferably urges theram 217 longitudinally forward so as to further insert the die assemblyinto the die cavity such that the pair of opposed forging dies 206 areradially closed about the continuous stock material. While the part isforged, the continuous stock material grows in both the upstream anddownstream longitudinal directions, as described above. In particular,the portion of the continuous stock material between the forged portionand the downstream clamp 252 will grow in a downstream longitudinaldirection, while the portion of the continuous stock material betweenthe forged portion and the upstream clamp 244 will grow in the upstreamlongitudinal direction.

The blade press forge 204 of the present invention compensates for thelongitudinal growth of the continuous stock material 12 in the upstreamlongitudinal direction by permitting the blade press carriage 232 tomove in a downstream longitudinal direction. In particular, the bladepress carriage will move in a downstream longitudinal direction by alinear distance equal to the growth of the continuous stock material inthe upstream longitudinal direction. Preferably, the blade press forgeincludes means, such as one or more hydraulic actuators 268 whicheffectively serve as springs, for longitudinally biasing the blade presscarriage so as to retard the downstream longitudinal movement of theblade press carriage, thereby encouraging lateral expansion of theforged portion of the continuous stock material such that the forgedportion fills the cavity defined by the pair of opposed forging dies206.

As illustrated in FIGS. 24 and 27, the clamp plate 258 in which thedownstream clamp 252 is disposed is mounted to the frame plate 230 ofthe blade press carriage 232. In particular, the clamp plate ispreferably mounted to the frame plate of the blade press carriage insuch a manner that the spacing or the distance between the clamp plateand the frame plate can be varied. In particular, the clamp plate ispreferably biased toward the frame plate of the blade press carriage,such as with one or more hydraulic springs 270.

By overcoming the bias force applied by the hydraulic springs 270,however, the clamp plate 258 and, therefore, the downstream clamp 252can be urged further away from the frame plate 228 of the blade presscarriage 232. According to the present invention, the growth of thecontinuous stock material 12 in the downstream longitudinal directionduring forging operations will supply a sufficient force to thedownstream clamp and, as a result, to the clamp plate so as to overcomethe predetermined bias force and to force the clamp plate further awayfrom the frame plate of the blade press carriage, thereby compensatingfor longitudinal growth of the continuous stock material on thedownstream longitudinal direction during the forging operation.

As described above in conjunction with the hex forge 50, the controller30 can be operably connected to one or more of the hydraulic springs 270such that the predetermined longitudinal bias force supplied by therespective hydraulic springs can be varied over time according to apredetermined schedule. For example, the controller can graduallyincrease the predetermined longitudinal bias force over time to ensurethat the portion of the continuous stock material 12 which is forgedwill expand laterally to fill the cavity defined by the forging dies206, while at the same time compensating for longitudinal growth of thecontinuous stock material during the forging operation.

The blade press forge 204 also preferably includes a pair of growthsensors for monitoring the longitudinal growth of the continuous stockmaterial 12. As shown in FIG. 20A, the blade press carriage positionsensor 240 measures the longitudinal growth of the continuous stockmaterial in the upstream longitudinal direction by monitoring thedownstream longitudinal movement of the blade press carriage 232. Asalso shown in FIG. 20A, the blade press forge also preferably includes adownstream growth sensor 274 which measures the longitudinal growth ofthe continuous stock material in the downstream longitudinal directionby monitoring the relative spacing of the clamp plate 258 from the frameplate 230 of the blade press carriage.

The controller 30 is operably connected to both the upstream anddownstream growth sensors such that by summing the respectivelongitudinal growth measured by both the growth sensors, the controllercan determine the total longitudinal growth of the continuous stockmaterial 12 in both longitudinal directions. Since the longitudinalgrowth of the continuous stock material is directly related to theextent of forging, the longitudinal growth of the continuous stockmaterial measured by the upstream and downstream growth sensors is, ineffect, a measurement of the extent of the forging which has beenconducted.

During forging operations of one advantageous embodiment, the bladepress 224 initially urges the die housing over the die assembly at arelatively rapid first predetermined rate, as shown in block 600. As theforging operations continue, however, the blade press preferably urgesthe die housing over the die assembly at a slower second predeterminedrate. For example, the blade press of one advantageous embodimentpreferably urges the die housing over the die assembly at a relativelyrapid rate until the controller 30 and the growth sensors determine thatthe combined longitudinal growth of the continuous stock material 12 inboth the upstream and downstream longitudinal directions equals apredetermined percentage, such as 90%, of the entire longitudinal growthof the continuous stock material anticipated during the blade pressforging operation. Once the predetermined percentage, such as 90%, ofthe total expected longitudinal growth of the continuous stock materialis reached, the blade press preferably slows the advancement of diehousing over the die assembly, while continuing to monitor thelongitudinal growth of the continuous stock material in both theupstream and downstream longitudinal directions. Once the controller andthe growth sensors determine that the longitudinal growth of thecontinuous stock material in both the upstream and downstreamlongitudinal directions equals the total anticipated longitudinal growthof the continuous stock material, the controller can halt furtheradvancement of the die housing over the die assembly, therebyterminating the forging of the blade portion of the spade bit. Seeblocks 602-614 of FIG. 55G and 55H.

Once the controller 30 has terminated forging operations, the bladepress 224 retracts or withdraws the ram 217 from the die assembly 206 asshown in block 616. As described above in conjunction with the hex forge50, the die assembly preferably includes a plurality of springs 276, oneof which is associated with each of the forging dies, for urging therespective forging dies in a radially outward direction. Therefore, asthe blade press retracts the die housing, the pair of opposed forgingdies open or moves radially outward so as to permit the continuous stockmaterial 12 to move longitudinally therethrough.

As shown in FIG. 20, the blade press forge also preferably includes asensor 278, such as an MTS Temposonics® LP position sensing system, formonitoring the relative position of the annular piston rod 228 of theblade press 224. As shown in blocks 618 and 620, the controller 30 isalso operably connected to the sensor so as to terminate the retractionof the annular piston rod once the annular piston rod has returned to apredetermined rest or initial position. Thereafter, the controller canopen the downstream clamp 252 by hydraulically rotating the lever arm264 such that the lever arm is also returned to its predeterminedinitial or rest position. Subsequently, the controller can open theupstream clamp 244 by hydraulically retracting the upstream closure 248.See blocks 622 and 624 of FIG. 55H.

As illustrated in FIG. 20A, the blade press forge 204 can also include apositioner, such as an AC servomotor and an associated ballscrew or, asillustrated, the hydraulic actuator 268, operably connected to the bladepress carriage 232 and responsive to commands from the controller 30.Accordingly, the controller can return the blade press carriage to apredetermined initial or starting position by actuating the hydraulicactuator which moves the blade press carriage to the initial or restposition as defined by the end of the threaded rod 280, as describedabove.

As shown in block 621 of FIG. 55H, once the controller 30 has terminatedforging operations and retracted the ram 217 of the blade press forge204, the ram can be rotated relative to the plurality of forging dies206 such that the wear and degradation of the die housing occasioned bythe relative motion of the ram and the plurality of forging dies isspread relatively evenly about the circumference of the ram. As shown inFIGS. 20 and 24, the blade press forge can include a rotator, such as atoothed gear 490 that is mounted to the ram and a drive member that isadapted to engage the gear and to cause the gear and, in turn, the ramto rotate. As described above in conjunction with the hex forge 50, thedrive member can be a rod which carries a pawl for engaging the toothedgear. As shown, the drive member is mounted to the blade press carriage232 and, more particularly, mounted upon a rear bolster plate of theblade press. Although the drive member can be actuated in a variety ofmanners, the drive member can be extended and retracted by means of ahydraulic actuator 492. In this regard, the hydraulic actuator canextend the ratchet by advancing the drive member in a downward directionsuch that the pawl can engage the gear and cause the gear to rotate by apredetermined angular amount in the counterclockwise direction. Once thegear has been rotated, the drive member is retracted by the hydraulicactuator. As described above, the pawl can be disengaged from the gearby pivoting the pawl away from the gear. Typically, the pawl is pivotedaway from the gear since the gear is adapted to rotate in only onedirection, such as the counterclockwise direction, such that attempts toretract the drive member will overcome the spring force which urges thepawl into engagement with the gear and permit the pawl to pivot out ofengagement with the gear. As will be apparent, a variety of other drivemembers, such as pinion gears or the like, can be utilized to rotate thegear and, in turn, the ram without departing from the spirit and scopeof the present invention.

Another technique for imparting relative rotation between the ram 217and the die assembly is illustrated in conjunction with the blade pressforge 204 of FIGS. 51-53. In this regard, a toothed gear 490 can bemounted to the ram for rotation therewith. In addition, the blade pressforge can include a drive gear 490 b, such as a pinion gear, whichengages the gear and is driven, such as by a motor 490 a, so as torotate the gear and, in turn, the ram. In order to permit the ram to beboth rotated and longitudinally advanced and retracted by the pistonrod, the piston rod is preferably connected to a rear portion of the ramby means of an internally threaded nut 447 which is threaded upon theforward end of the piston rod and which is also rotatably connected to aconnector plate 448 that is attached to the rear portion of the ram.More particularly, the nut of the illustrated embodiment is retainedwithin a recess defined by a central portion of the connector plate bymeans of a plurality of cam followers 449. As best shown in FIG. 53, oneend of each cam follower rides within a circumferential groove definedby the nut, while the other end of each cam follower is retained withina respective opening defined by the connector plate so as to permitrelative rotation between the ram and the piston rod while continuing toallow the piston rod to longitudinally advance and retract the ram.

Preferably, the ram 217 is incrementally rotated after a predeterminednumber of parts have been formed, such as after each part has beenformed. Although the ram can be rotated by different predeterminedamounts, the ram is generally rotated between 10° and 30° and, moretypically, by about 20°. By repeatedly incrementally rotating the ram,however, the ram will eventually be rotated completely about the dieassembly, that is, through an entire 360°. As such, the rotation of theram relative to the die assembly will more evenly distribute the wearabout the die cavity. In addition, the rotation of the ram relative tothe die assembly will maintain the generally cylindrical shape of theram and substantially prevent the forward end of the ram from assumingan oval shape or from otherwise being deformed during forging operationsas has occurred to rams of conventional forges.

Although not illustrated, the blade press die assembly could be rotatedin addition to or instead of rotating the ram 217. In addition topromoting more even wear of the die housing, rotation of the blade pressdie assembly would also allow different parts to be forged intorespective predetermined shapes which are disposed at different angularorientations relative to the continuous stock material, thereby furtherincreasing the versatility of the forming method and apparatus 10 of thepresent invention.

The blade press forge 204 can also include a sensor 494 for detectingrotation of the ram 47 relative to the die assembly. By monitoring therotation sensor to the controller 30, the controller can determine ifthe ram has been rotated relative to the die assembly following aforging operation and can prevent further forging operations until theram has been appropriately rotated.

The blade press forge 204 can also include a lubrication system 496 forproviding lubricant to the die assembly, the ram 217 including the diehousing 60 and the head 218. Typically, the lubricant is an oil, such asmachine way lube. However, the lubrication system can apply otherlubricants, if so desired. According to this embodiment, a plurality ofports 497 are defined through the head and the ram so as to open intothe die cavity within which the die assembly is inserted. See FIGS. 25and 26. By injecting lubricant through these ports, the lubricationsystem can therefore provide lubricant to the back surfaces 432 of theforging dies 206.

The controller 30 typically controls the operation of the lubricationsystem 496, such as the pneumatically activated solenoid valve 496 a andthe servovalves 496 b which control the flow of lubricant in theillustrated embodiment. Typically, the controller directs thelubrication system to provide lubricant following each forging operationby injecting lubricant through the ports 497 once the ram 61 has beenlongitudinally retracted and while the back surfaces 432 of the forgingdies 206 are at least somewhat exposed. See block 619 of FIG. 55H. Whilelubricant is injected at a plurality of discrete ports, such as threeports, the subsequent rotation of the ram relative to the die assemblyserves to distribute the lubricant relatively evenly between the ram andthe back surfaces of each of the forging dies.

The lubrication system 496 can also provide lubricant between the head218 and the ram 217 in order to facilitate the lengthwise advancementand retraction of the ram within the passageway defined by the head. Inthis regard, at least one and, more commonly a pair of ports 498 can bedefined through the head such that lubricant injected through theseadditional ports is spread over the outer surface of the ram and theinner surface of that portion of the head which defines the passageway.To facilitate even distribution of the lubricant about the entirecircumference of the ram, the head preferably defines a pair ofcircumferentially extending grooves 499. By injecting lubricant into thecircumferential groove, lubricant is effectively applied about theentire circumference of the ram, thereby evenly lubricating the ram.Alternatively, the ram can define the circumferential groove instead ofor in addition to the head, if so desired.

As shown in FIGS. 24-26, an additional port 495 can be defined by a rearportion of the head 218 and the bushing 440 to provide lubricant betweenthe bushing and the ram 217. In a like manner to that described above,bushing and/or the ram can define a circumferentially extending groove493 in order to spread the lubricant evenly about the circumference ofthe bushing and the ram.

As described above, the controller 30 typically directs the lubricationsystem 496 to inject lubricant once the ram 217 has been fullyretracted. However, lubricant can be injected at other times during theforging process, if desired. Thus, the lubrication system of the bladepress 204 forge of this advantageous embodiment can repeatedly lubricatethe various components of the forge in order to reduce wear and increasethe effective life of the components without applying enough lubricantto the continuous stock material 12 that the continuous stock materialbecomes difficult to grip during downstream operations.

In the illustrated embodiment, once all of the forging operations havebeen completed, the controller 30 can extend the annular piston rod ofthe indexer 14 such that the indexer clamp 16 is brought to apredetermined starting or initial position. See blocks 626-630.Thereafter, the controller can close the indexer clamp as describedabove so as to securely grip a portion of the continuous stock material12 and, following a predetermined dwell time, such as 0.1 seconds, thecontroller can release the upstream turning head clamp 44. See blocks632-636 of FIG. 55I. In embodiments of the present invention in whichthe spur trimming station 116 and/or the outside diameter trimmingstation 138 are utilized as a downstream indexer, the spur trim clamps134 and the outside diameter trim clamps 156 are also extended so as tosecurely grip the continuous stock material along with the upstreamindexer. Thereafter, the steps of the forging method of the presentinvention which are described above and illustrated in FIGS. 55A-55I canbe repeated. See block 638.

Following separation of a forged part from the continuous stock material12, the part preferably undergoes a number of finishing operations. Inorder to further increase the efficiency of the forming method andapparatus 10 of the present invention, these finishing steps can beconducted at the same time as the second or blade forging operations.However, these finishing operations can also be performed at a latertime without departing from the spirit and scope of the presentinvention.

As shown schematically in FIGS. 1 and 2, the forming apparatus 10 of oneembodiment of the present invention can include a conveyor or other typeof collection system for collecting and transporting the resulting partsin a controlled fashion. According to one embodiment of the presentinvention, the resulting parts are thereafter heat treated and shotblasted, prior to undergoing finishing operations and being packaged forshipment and sale. See blocks 308-312 of FIG. 1. These finishingoperations can include grinding operations and rust inhibitingoperations. The grinding operations are typically performed by anumerically controlled grinder which, in one embodiment, serves tofurther sharpen and define the forward cutting edges of the resultingspade bit. In contrast to conventional grinding process which grind theouter diameter of the spade bit 410 prior to grinding the spur and theforward cutting edges, the grinding process of one advantageousembodiment initially grinds the cutting edges including the forwardcutting edges 434 and the spur cutting edges 432. Thereafter, the outerdiameter can be ground without damaging the previously ground cuttingedges. In addition, the clamps utilized to hold the spade bit during thegrinding operations can also be utilized to check the straightness ofthe spade bit and to check the shape of the hexagonal rear portion 416of the shank 412 such that imperfectly formed spade bits can be detectedand removed prior to the final finishing operations.

As depicted in block 500 of FIG. 55A, the forming apparatus 10 must beinitially loaded prior to commencing the forming operations. Thus, theforming apparatus preferably includes a load clamp 314 for securelygripping the continuous stock material 12 during loading operations. Asshown in FIG. 7, the load clamp preferably includes an annular collet315 through which the continuous stock material extends. The load clampcan also include a load closure 317 and a hydraulic cylinder assembly319, operably connected to the load closure and responsive to commandsfrom the controller 30. In order to load the continuous stock materialinto the forming apparatus of this advantageous embodiment, thecontroller can close the load clamp, such as by hydraulically advancingthe load closure over the load collet such that the load collet movesradially inward and securely grips the continuous stock material. Thecontroller also preferably opens all of the other clamps, such as theindexer clamp 16, the upstream and downstream turning head clamps 44 and47 and the upstream and downstream blade press clamps 244 and 252, suchthat the continuous stock material can be extended therethrough.

The forming apparatus 10 and, more particularly, the controller 30 thenadvances the load clamp 314 by a predetermined linear distance in adownstream longitudinal direction such that the continuous stockmaterial 12 is also advanced by the predetermined linear distance in thedownstream longitudinal direction. In particular, the indexer piston rodcan be operably connected to the load clamp such that hydraulicactuation of the indexer clamp cylinder can advance the load clamp inthe downstream longitudinal direction. In this regard, the load clampcan include one or more slides 321 which ride upon or cooperate with thelongitudinally extending, parallel rails or tracks 39.

The controller 30 then opens the load clamp 314, such as hydraulicallyretracting the load closure such that the annular load collet opens.Once the load clamp has been opened, the controller moves the load clampby the same predetermined linear distance in the upstream longitudinaldirection such that the load clamp returns to a predetermined initial orrest position as shown by FIG. 7. For example, in the illustratedembodiment, the controller can hydraulically actuate the indexer clampcylinder so as to urge the indexer piston rod and, therefore, the loadclamp in an upstream longitudinal direction. The controller can thenrepeat the steps of closing the load clamp about the continuous stockmaterial, advancing the load clamp in the downstream longitudinaldirection, opening the load clamp and returning the load clamp to thepredetermined initial or rest position for as many cycles as required inorder to feed the leading end of the continuous stock material 12through the forming apparatus 10.

Although the forming method and apparatus 10 of one embodiment of thepresent invention has been described above in considerable detail, itshould be apparent to those skilled in the art that variousmodifications can be made to the forming method and apparatus withoutdeparting from the spirit and scope of the present invention. Forexample, in one alternative embodiment of the forming method andapparatus of the present invention, the turning head 45 is not disposedbetween the hex forge 50 and the blade press forge 204, but is, instead,disposed downstream of the forging, trimming and sawing operations. Assuch, the turning head can machine the ball groove 110 and chamferededge 112 in an extremely precise manner with respect to one end,typically the rear end, of the resulting part. If the turning head weredisposed downstream of the forging, trimming and sawing operations, theforming apparatus of this embodiment would preferably include a clampdisposed between the hex forge and the blade press forge so as to clampa fixed portion of the continuous stock material 12 during the forgingand trimming operations. Thus, the fixed clamp functions would in asimilar fashion to the upstream turning head clamp 44 of the embodimentdescribed hereinabove.

For a forming apparatus 10 adapted to fabricate parts of a predeterminedlength, the initial or rest position of the blade press forge 204 can befixed and need not be adjusted to compensate for the longitudinal growthof the continuous stock material 12 created during the hex forgingoperations. Instead, the separation between the respective initial orrest positions of the hex forge 50 and the blade press forge 204 can bedetermined based upon the length of the resulting part, the stroke ofthe indexer 14 and the anticipated longitudinal growth of the continuousstock material in a downstream longitudinal direction during the hexforging operations. Preferably, the separation between the hex forge andthe blade press forge is minimized in order to further improve thequality and tolerance control of the resulting parts. For example, thehex forge and the blade press forge of one advantageous embodiment areseparated by about 24 inches.

As described above, the predetermined initial or rest position of theblade press forge 204 need not be adjusted to compensate for variationsin the growth of the continuous stock material 12 in the downstreamlongitudinal direction which were created during the hex forgingoperations, such as by detecting a registration feature 104 andadjusting the position of the blade press forge relative to the detectedregistration feature. If desired, however, the continuous stock materialcan include a plurality of registration features spaced longitudinallyalong its length which can be detected by the blade press forge in themanner described above. Thus, the forming apparatus can include a bladepress forge which is adapted to detect registration features during theintermittent advance of the continuous stock material and to adjust itsposition relative to the most recently detected registration featureprior to blade press forging operations. For example, the blade pressforge 204 of this embodiment can include a registration monitor fordetecting the registration feature such that the relative position ofthe blade press forge can be thereafter adjusted relative to thedetected registration feature in a similar manner to that describedabove.

Although one advantageous set of trimming and sawing operations has beendescribed above, the forming method and apparatus 10 of the presentinvention can include a variety of trimming operations without departingfrom the spirit and scope of the present invention. For example, theforming method and apparatus and apparatus of the present invention caninclude a left side trimming station and a right side trimming stationfor trimming the left and right sides of the resulting part,respectively. With respect to a forming method and apparatus adapted tofabricate spade bits, the left and right side trimming stations can trimthe left and right sides, respectively, of the blade portion of thespade bit, including the left and right sides, respectively, of thespur. Thus, upon the completion of the final trimming operation, theresulting part will be separated from the preceding or downstream partand the leading end of the part, such as the spur, will be completelytrimmed.

In this embodiment, the left and right side trimming stations preferablyinclude respective registration monitors, such as photosensors, fordetecting the registration features. The left and right side trimmingstations also preferably include means, such as a hydraulic cylinderassembly or an AC servomotor and an associated ballscrew, for moving therespective stations in a longitudinal direction relative to the detectedhole such that the left and right side trimming stations are preciselyaligned with the portion of the part to be trimmed. As also describedabove, the left side trimming station and the right side trimmingstation can be operating on different ones of the plurality of parts atthe same time.

For embodiments of the forming method and apparatus 10 which are adaptedto fabricate spade bits, it has been observed that the blade forgingoperation requires a significantly longer time to complete than theother operations which are performed. Thus, even though theabove-described forming method and apparatus is particularly well suitedfor processing a continuous stock material 12, it is contemplated thatthe forming method and apparatus of one embodiment could include aplurality of blade press forges 204. As described hereinbelow, theplurality of blade press forges can operate in parallel in order toincrease the throughput of the resulting forming apparatus.Alternatively, the plurality of blade press forges can be disposed inseries such that different ones of the forges operate on different onesof the parts.

Therefore, the saw station 160 of the forming apparatus 10 of thisembodiment can be disposed downstream of the hex forge 50 so as toseparate the continuous stock material 12 into a number of discrete,partially formed parts. The forming apparatus of this embodiment canalso include a plurality of transfer mechanisms which engage respectiveones of the discrete parts and which transfer the respective parts tocorresponding blade press forges 204. For example, the transfermechanism can include a clamp for engaging a predetermined portion ofthe partially formed part. Thereafter, the transfer mechanism can eithertransport the respective part to the corresponding blade press forge or,alternatively, the respective blade press forge can be moved intoengagement with the respective part. Since the transfer mechanism hasalready engaged a predetermined portion of the respective part, such asthe connector 200 which extends between adjacent parts, the transfermechanism can serve as the downstream blade press clamp during theensuing blade forging operations. Thereafter, the forged parts can betrimmed and processed as described above. For example, the forged partscan be trimmed and processed by a single trimming and processing line,disposed downstream at the plurality of blade press forges.Alternatively, the forged parts can be trimmed and processed in parallelby separate trimming and processing lines without departing from thespirit and scope of this aspect of the present invention.

While the forming method and apparatus 10 of the present invention canbe employed to manufacture a number of different types of parts, theforming method and apparatus of one advantageous embodiment fabricates aplurality of spade bits 410 from a continuous stock material 12. Thus, aspade bit which could be manufactured according to one advantageousembodiment of the present invention will be described in more detailhereinbelow.

As illustrated in FIGS. 4-6, a spade bit 410 of the present inventionincludes an elongate shank 412 defining a central longitudinal axis 414.The rear portion 416 of the shank is adapted to be received and held bya drill (not illustrated). For example, the elongate shank typicallyincludes a cylindrical forward portion and a rear portion that ishexagonal in transverse cross-section so as to be securely received andheld by the chuck of a drill (not illustrated).

The spade bit 410 also includes a blade portion 418 joined to a forwardend of the elongate shank 412. The blade portion includes a pair ofgenerally flat side segments 420 which extend laterally in oppositedirections from the central longitudinal axis 414. The side segmentspreferably define respective lateral planes which are parallel to eachother and the central longitudinal axis. According to this embodiment ofthe present invention, the blade portion also includes a generally flatcentral segment 424 disposed along the central longitudinal axis anddefining a central plane. More particularly, the central segmentincludes opposite sides 428 which are parallel to the centrallongitudinal axis, a rear end which is continuous with the forward endof the shank and an opposite forward end. According to this embodiment,the pair of side segments or wings are continuous with the centralsegment along respective sides of the central segment. In particular,the pair of side segments are continuous with respective sides of thecentral segment such that lateral planes defined by the respective sidesegments intersect the central plane defined by the central segment atan oblique angle.

Each side segment 420 can also include a respective chamfered cornerportion 435. Each chamfered corner portion includes a chamfered edgewhich extends both axially rearward and laterally outward from therespective forward cutting edge 434, 436. In particular, the forwardcutting edge of each side segment typically extends laterally outwardfrom an inner portion to an outer portion. Accordingly, the chamferededge of each chamfered corner portion preferably extends both axiallyrearward and laterally outward from the outer portion of the respectiveforward cutting edge. Preferably, the chamfered edges are defined suchthat a line parallel to the central longitudinal axis 414 and thechamfered edge of each respective side segment defines a chamfer angle435 a of between about 30° and about 60° therebetween.

Each chamfered corner portion 435 also includes a chamfer surface whichslopes radially inward from the respective chamfered edge to a rearedge. Preferably, the chamfer surfaces are defined so as to have achamfered clearance angle 437 of between about 10° and about 20°, asshown in FIG. 6A. In this regard, the chamfered clearance angle isdefined as the angle between a chamfered plane defined by a chamfersurface and a plane perpendicular to a lateral plane defined by arespective side segment.

By extending both axially rearward and laterally outward from therespective forward cutting edge 434, 436, the chamfered corner portions435 can repeatedly cut the peripheral wall of the resulting hole as thespade bit 410 of the present invention is rotatably advanced through theworkpiece. Therefore, the spade bit of the present invention canefficiently produce high-quality holes having smooth peripheral wallsand relatively clean entry and exit points.

The blade portion 418 also includes a spur 430 extending axially fromthe forward end of the blade portion to center and to guide the spadebit 410 during drilling operations. As best illustrated in FIG. 6, thespur of this embodiment is of a generally triangular shape and extendsto a spur point on the central longitudinal axis 414. The spur alsoincludes a pair of spur cutting edges 432 extending along opposite sidesof the spur between the spur point and a base of the spur at the forwardend of the blade portion. The spur cutting edges are positioned toinitially contact the workpiece during rotation of the spade bit in thepredetermined direction of rotation as indicated by the clockwise arrowin FIG. 4.

Each side segment 420 also includes a respective forward cutting edge.According to one advantageous embodiment, the respective forward cuttingedges of each side segment are preferably axially offset. In otherwords, the spade bit of one advantageous embodiment includes an axiallyadvanced forward cutting edge 434 and an axially rearward cutting edge436. In particular, the respective forward cutting edges of the sidesegments are preferably axially offset by a predetermined axial amountD, such as between about 0.010 inch and about 0.012 inch in oneadvantageous embodiment. Typically, the axial offset of the respectiveforward cutting edges is ground into the forward cutting edges duringgrinding operations following the forming method and apparatus 10described above. By being axially offset, the respective forward cuttingedges contact and remove material in an efficient manner as the spadebit 410 rotates in a predetermined direction of rotation during drillingoperations. In addition, since the forward cutting edges are axiallyoffset, the spade bit of this advantageous embodiment of the presentinvention preferably has a relatively long life due to the efficientremoval of material as a spade bit advances through a workpiece.

The alignment of the forward cutting edges, 434, 436 of the sidesegments 420 along a centerline 421 that passes through the centrallongitudinal axis 414 further improves the performance of the spade bit410 by directing the removed chip swarf perpendicularly from the cuttingedge and upwardly, and not radially outwardly. As a result, the chipswarf does not hinder subsequent rotation of the spade bit by bindingbetween the spade bit and the sidewalls of the hole formed thereby.Accordingly, the longevity of the spade bit is increased by reducing thewear on the spade bit and the efficiency with which the spade bit drillsa hole of a predetermined diameter is enhanced.

According to one advantageous embodiment, each spur cutting edge 432preferably extends radially outward of at least an innermost portion ofthe forward cutting edge of the adjacent side segment 420. Thus, eachspur cutting edge is radially separated from the forward cutting edge ofthe adjacent side segment. In addition, the spur 430 preferably definesa spur plane which is oblique to the respective lateral planes definedby the side segments such that each spur cutting edge is also preferablyangularly offset as shown at 431 from the forward cutting edge of theadjacent side segment in the predetermined direction of rotation of thespade bit 410 when viewed along the central longitudinal axis 414. Inparticular, each spur cutting edge is positioned angularly rearward ofthe forward cutting edge of the adjacent side segment in thepredetermined direction of rotation. Thus, each spur cutting edge isalso angularly separated from the forward cutting edge of the adjacentside segment. Further, at least a portion of each spur cutting edgeextends axially rearward of the forward cutting edge of the adjacentside segment in the longitudinal direction so that each spur cuttingedge is also axially separated from the forward cutting edge of theadjacent side segment.

A forward portion of each side segment preferably defines a cuttingplane. The cutting plane intersects the lateral plane defined by therespective side segment 420 to define a hook angle therebetween.Preferably, the hook angle 433 is between about 10° and about 20° and,more preferably, is about 15°, as shown in FIG. 6B. The forward cuttingedges of the illustrated embodiment are disposed angularly in advance ofthe lateral planes of the respective side segments in the predetermineddirection of rotation of the spade bit 410 when viewed along the centrallongitudinal axis 414. Chips removed from the workpiece by the forwardcutting edge are thereby directed upwardly or rearwardly along the spadebit and away from the cutting surface by further rotation of the spadebit, and, in part, by the hook angle defined between the cutting planeand the lateral plane.

Further, each side segment 420 of the spade bit 410 can also include aforward end having a forward end surface 425 extending between therespective forward cutting edge and a rear edge 426. Advantageously, theforward end surface slopes rearwardly from the forward cutting edge tothe rear edge such that only the forward cutting edge contacts thecutting surface during drilling operations. Thus, the drag or otherfrictional forces generated between the rotating spade bit and theworkpiece are reduced and the efficiency with which the spade bit of thepresent invention drills is further improved.

Each forward end surface preferably includes first and second forwardend planes which intersect a plane perpendicular to the centrallongitudinal axis 414 to define primary and secondary lip clearanceangles, respectively, therebetween. The secondary lip clearance angle istypically larger than the primary lip clearance angle in order tofurther reduce drag or other frictional forces generated between therotating spade bit and the workpiece. For example, in one embodiment,the primary and secondary lip clearance angles are about 5° and 8°,respectively, as shown in FIG. 6B. However, the primary and secondarylip clearance angles can be varied without departing from the spirit andscope of the present invention. In addition, the forward end surfaceneed not include both first and second forward end planes asillustrated, but can, instead, include a single forward end planewithout departing from the spirit and scope of the present invention.

Still further, each side segment 420 of the illustrated embodiment ofthe spade bit 410 of the present invention includes a first side joinedto the central segment 424 along a side 428 thereof, and an opposedsecond side 429 defining a second or outer side surface. The second orouter side surface extends between respective forward and rear edges andpreferably follows the arc of a circle in lateral cross-section tofurther reduce the drag or other frictional forces generated by therotation of the spade bit within the hole. Alternatively, the sidesurface can taper radially inwardly from the forward edge to the rearedge such that only the forward edge of the side surface of the sidesegment contacts the sidewalls of the hole to thereby further reducebinding of the spade bit.

The second sides 429 of the respective side segments 420 also preferablytaper inwardly in an axial direction from the forward end to the rearend of the blade portion 418. Thus, a side surface taper angle 429 a,typically, about one-half of 1°, or ½°, is defined between the sidesurface plane and a line parallel to the central longitudinal axis 414.By tapering the second sides of the side segments inwardly, the sidesurfaces preferably only contact the workpiece near the cutting surfacesuch that drag or other frictional forces are still further reduced.

While one particularly advantageous spade bit 410 is illustrated inFIGS. 4-6 and described herein, the spade bit can have many otherconfigurations without departing from the spirit and scope of thepresent invention. In this regard, U.S. Pat. Nos. 5,697,738 and5,700,113, the contents of both of which have been expresslyincorporated by reference herein, describe several other embodiments ofa spade bit which could also be fabricated by the forming method andapparatus 10 of the present invention.

Regardless of the type of part, the forming method and apparatus 10 ofthe present invention provides numerous advantages over conventionalfabrication processes. In particular, by processing the plurality ofparts while still joined by the continuous stock material 12, the amountof handling and transporting of discrete parts is significantly reduced.In addition, the forming method and apparatus of the present inventionis able to maintain a precise alignment between the partially formedparts and the various stations of the forming apparatus so as to producehigh quality parts having sharply defined features, such as, forexample, the above-described radial, angular and longitudinal separationof the spur cutting edge 432 from the forward cutting edges 434 and 436of the respective side segments 420 of the blade portion 418 of thespade bit 410 of the present invention. By altering the stroke of theindexer 14, parts of various lengths can be produced from the samecontinuous metal stock, such as spade bits having an elongate shank ofvarious lengths. Moreover, since the forming method and apparatus of thepresent invention performs several operations at the same time, albeiton different parts at different positions along the fabrication line,the forming method and apparatus can efficiently form a plurality ofparts of a predetermined shape.

In the drawings and the specification, there has been set forth apreferred embodiment of the invention and, although specific terms areemployed, the terms are used in a generic and descriptive sense only andnot for purpose of limitation, the scope of the invention being setforth in the following claims.

That which is claimed is:
 1. A method of forming a plurality of partsfrom a continuous stock material, the method comprising: intermittentlyadvancing the continuous stock material along a predetermined path suchthat the stock material advances longitudinally in a downstreamdirection; forming a portion of the continuous stock material into afirst predetermined shape at a forming station following at least oneintermittent advancement of the continuous stock material, whereinforming the portion of the continuous stock material comprises causinglongitudinal growth of the continuous stock material; and at leastpartially compensating for the longitudinal growth of the continuousstock material caused by forming the portion of the continuous stockmaterial; wherein intermittently advancing the continuous stock materialcomprises: intermittently pushing the continuous stock material in thedownstream direction from a location spaced in an upstream directionfrom the forming station; and intermittently pulling the continuousstock material in the downstream direction from a location spaced in thedownstream direction from the forming station, wherein the intermittentpushing and pulling are synchronized such that the continuous stockmaterial is advanced longitudinally in the downstream direction alongthe predetermined path.
 2. A forming method according to claim 1 whereinintermittently pushing the continuous stock material comprisesintermittently pushing the continuous stock material a predetermineddistance in the downstream direction, and wherein intermittently pullingthe continuous stock material comprises intermittently pulling thecontinuous stock material the same predetermined amount in thedownstream direction such that the continuous stock material isintermittently advanced by the predetermined amount in the downstreamdirection.
 3. A forming method according to claim 1 whereinintermittently pulling the continuous stock material and intermittentlypushing the continuous stock material are synchronized such that thecontinuous stock is concurrently pulled and pushed in the downstreamdirection.
 4. A forming method according to claim 1 wherein at leastpartially compensating for the longitudinal growth of the continuousstock material caused by forming the portion of the continuous stockmaterial comprises allowing movement of the continuous stock material ina longitudinal direction away from the formed portion of the continuousstock material.
 5. A forming method according to claim 4 furthercomprising clamping a fixed portion of the continuous stock materialfollowing at least one intermittent advancement of the continuous stockmaterial so as to securely hold the fixed portion of the continuousstock material, wherein forming the portion of the continuous stockmaterial comprises forming the portion of the continuous stock materialwhile the fixed portion of the continuous stock material is clamped at alocation disposed in a predetermined longitudinal direction from theformed portion of the continuous stock material, and wherein said atleast partial compensation for the longitudinal growth of the continuousstock material comprises allowing movement of the continuous stockmaterial in a longitudinal direction opposite the predeterminedlongitudinal direction.
 6. A forming method according to claim 5 whereinforming the portion of the continuous stock material includes at leastpartially closing a plurality of dies about the continuous stockmaterial, wherein the plurality of closed dies define a cavity of apredetermined shape which defines the shape of at least a portion of theresulting part, and wherein the plurality of at least partially closeddies define entry and exit ports through which the continuous stockmaterial extends while the portion of the continuous stock material isformed.
 7. A forming method according to claim 6 wherein the pluralityof dies are mounted on a carriage which is adapted to movelongitudinally, and wherein the forming method further comprisesadditionally compensating for the longitudinal growth of the continuousmaterial by mounting the carriage such that the longitudinal growth ofthe continuous stock material between the formed portion of thecontinuous stock material and the fixed portion of the continuous stockmaterial causes the carriage to move in a longitudinal directionopposite the predetermined longitudinal direction such that theplurality of dies remain at least partially closed about the sameportion of the stock material during the formation of the portion of thecontinuous stock material.
 8. A forming method according to claim 7further comprising longitudinally biasing the carriage on which theplurality of dies are mounted with a predetermined longitudinal biasforce so as to retard longitudinal movement of the carriage.
 9. Aforming method according to claim 6 further comprising: opening theplurality of dies after forming a portion of the stock material;releasing the clamped portion of the stock material such that thecontinuous stock material can be advanced along the predetermined path;and repeating the method to form at least a portion of another part. 10.A forming method according to claim 4 further comprising: monitoring thelongitudinal growth of the continuous stock material; and terminatingthe formation of the portion of the continuous stock material once thelongitudinal growth of the continuous stock material is at least asgreat as a predetermined longitudinal growth threshold.
 11. A formingmethod according to claim 5 further comprising: forming another portionof the continuous stock material into a second predetermined shape whilethe fixed portion of the continuous stock material is clamped; releasingthe fixed portion of the continuous stock material following saidforming of respective portions of the continuous stock material intofirst and second predetermined shapes such that the continuous stockmaterial can be advanced along the predetermined path; and repeating themethod such that the resulting parts have both the first and secondpredetermined shapes.
 12. A forming method according to claim 1 furthercomprising: trimming predetermined portions of each part followingformation of the portion of the continuous stock material; and cuttingeach trimmed part from the continuous stock material to thereby separatethe continuous stock material into a plurality of discrete parts.
 13. Aforming method according to claim 5 further comprising: forming aregistration feature in a predetermined portion of each part while thecontinuous stock material is clamped; and trimming predeterminedportions of each part which are disposed in a predetermined positionalrelationship to the registration feature following formation of theportion of the continuous stock material.
 14. A method of forming aplurality of parts from a continuous stock material, wherein theplurality of parts comprise a plurality of spade-type boring bits, themethod comprising: intermittently advancing the continuous stockmaterial along a predetermined path such that the stock materialadvances longitudinally in a downstream direction; and forming a portionof the continuous stock material into a first predetermined shape at aforming station following at least one intermittent advancement of thecontinuous stock material, wherein forming the portion of the continuousstock material into the first predetermined shape comprises forming aportion of the continuous stock material into a blade portion of therespective spade-type boring bit; wherein intermittently advancing thecontinuous stock material comprises: intermittently pushing thecontinuous stock material in the downstream direction from a locationspaced in an upstream direction from the forming station; andintermittently pulling the continuous stock material in the downstreamdirection from a location spaced in the downstream direction from theforming station, wherein the intermittent pushing and pulling aresynchronized such that the continuous stock material is advancedlongitudinally in the downstream direction along the predetermined path.15. An apparatus for forging a plurality of parts from a continuousstock material, the apparatus comprising: a plurality of indexers whichare synchronized to intermittently advance the continuous stock materialalong a predetermined path such that the stock material advanceslongitudinally in a downstream direction through the forging apparatus;a clamp which clamps and securely holds a fixed portion of thecontinuous stock material following at least one intermittent advance ofthe continuous stock material; and a forge which forges a portion of thecontinuous stock material into a first predetermined shape following atleast one intermittent advancement of the continuous stock material,wherein said forge forges the portion of the continuous stock materialand creates longitudinal growth thereof while said clamp securely holdsthe fixed portion of the continuous stock material at a locationdisposed in a predetermined longitudinal direction from the forgedportion of the continuous stock material, wherein said plurality ofindexers comprise: an upstream indexer for intermittently pushing thecontinuous stock material in the downstream direction, said upstreamindexer disposed upstream of said forge; and a downstream indexer forintermittently pulling the continuous stock material in the downstreamdirection, said downstream indexer disposed downstream of said forge,wherein said upstream and downstream indexers are synchronized tolongitudinally advance the continuous stock material in the downstreamdirection along the predetermined path, and wherein the forgingapparatus at least partially compensates for longitudinal growth of thecontinuous stock material created by said forge.
 16. A forging apparatusaccording to claim 15 wherein said upstream indexer intermittentlypushes the continuous stock material a predetermined distance in thedownstream direction, and wherein said downstream indexer intermittentlypulls the continuous stock material the same predetermined amount in thedownstream direction such that the continuous stock material isintermittently advanced by the predetermined amount in the downstreamdirection.
 17. A forging apparatus according to claim 15 wherein saidupstream and downstream indexers are synchronized such that saidupstream and downstream indexers concurrently pull and push thecontinuous stock material in the downstream direction.
 18. A forgingapparatus according to claim 15 wherein said forge comprises: aplurality of dies disposed about the continuous stock material; andmeans for at least partially closing said plurality of dies about thecontinuous stock material, wherein said plurality of dies define acavity of a predetermined shape which defines the shape of at least aportion of the resulting part, and wherein said plurality of dies defineentry and exit ports through which the continuous stock materialextends.
 19. A forging apparatus according to claim 15 wherein theforging apparatus at least partially compensates for longitudinal growthof the continuous stock material created by said forge by allowingmovement of the continuous stock material in a longitudinal directionaway from said forge and opposite the predetermined longitudinaldirection.
 20. A forging apparatus according to claim 19 wherein saidforge further comprises a carriage on which said plurality of dies aremounted, and wherein said carriage is mounted so that the longitudinalgrowth of the continuous stock material between the forged portion ofthe continuous stock material and the fixed portion of the continuousstock material causes said carriage to move in a longitudinal directionopposite the predetermined longitudinal direction such that saidplurality of dies remain at least partially closed about the sameportion of the stock material during forming of the continuous stockmaterial.
 21. A forging apparatus according to claim 20 wherein saidforge further comprises biasing means for longitudinally biasing saidcarriage with a predetermined longitudinal bias force so as to retardlongitudinal movement of said carriage.
 22. A forging apparatusaccording to claim 19 wherein the continuous stock material includes aplurality of longitudinally spaced apart registration features, whereinthe forging apparatus further comprises: a sensor for identifying aregistration feature on the continuous stock material; and a positioner,responsive to said sensor, for positioning said clamp such that thefixed portion of the continuous stock material which is clamped islongitudinally spaced from the registration feature by a predetermineddistance.
 23. A forging apparatus according to claim 19 furthercomprising a second forge, longitudinally spaced from said first forge,which forges another portion of the continuous stock material into asecond predetermined shape while said clamp securely holds the fixedportion of the continuous stock material such that the resulting partshave both the first and second predetermined shapes imparted by saidfirst and second forges, respectively.
 24. A forging apparatus accordingto claim 19 further comprising: a longitudinal growth monitor formonitoring the longitudinal growth of the continuous stock materialduring forging of the continuous stock material into the firstpredetermined shape; and a controller, responsive to said longitudinalgrowth monitor, for terminating forging operations once the longitudinalgrowth of the continuous stock material is at least as great as apredetermined longitudinal growth threshold.
 25. An apparatus forforging a plurality of parts from a continuous stock material, theapparatus comprising: a plurality of indexers which are synchronized tointermittently advance the continuous stock material along apredetermined path such that the stock material advances longitudinallyin a downstream direction through the forging apparatus; and a forgewhich forges a portion of the continuous stock material into a firstpredetermined shape following at least one intermittent advancement ofthe continuous stock material, wherein said forge comprises: a pluralityof dies disposed about the continuous stock material; and means for atleast partially closing said plurality of dies about the continuousstock material, wherein said plurality of dies define a cavity of apredetermined shape which defines the shape of at least a portion of theresulting part, and wherein said plurality of dies define entry and exitports through which the continuous stock material extends, wherein atleast one die includes a contact surface which defines a contact planeand which further defines a portion of the cavity for contacting andshaping a portion of the continuous stock material into thepredetermined shape of the resulting part, wherein said means for atleast partially closing said dies comprises a die housing defining aninternal cavity for receiving and circumferentially encompassing saidplurality of dies, wherein said plurality of dies are at least partiallyclosed upon insertion of said dies into said die housing such that saiddies move inward in a predetermined direction, and wherein thepredetermined direction is oblique to the respective contact planes ofsaid dies such that the respective contact surfaces impart both axialand radial forces to at least portions of the continuous stock materialto generate compressive and shear forces within the continuous stockmaterial and to form at least a portion of the part within the cavitydefined between said plurality of dies; wherein said plurality ofindexers comprise: an upstream indexer for intermittently pushing thecontinuous stock material in the downstream direction, said upstreamindexer disposed upstream of said forge; and a downstream indexer forintermittently pulling the continuous stock material in the downstreamdirection, said downstream indexer disposed downstream of said forge,wherein said upstream and downstream indexers are synchronized tolongitudinally advance the continuous stock material in the downstreamdirection along the predetermined path.
 26. A forging apparatusaccording to claim 25 wherein the contact plane of at least one die anda reference plane perpendicular to the predetermined direction ofmovement of said at least one die define an angle of between about 10°and about 20° therebetween.
 27. An apparatus for forging a plurality ofparts from a continuous stock material, wherein the continuous stockmaterial includes a plurality of longitudinally spaced apartregistration features, wherein the forging apparatus comprises: aplurality of indexers which are synchronized to intermittently advancethe continuous stock material along a predetermined path such that thestock material advances longitudinally in a downstream direction throughthe forging apparatus; a forge which forges a portion of the continuousstock material into a first predetermined shape following at least oneintermittent advancement of the continuous stock material; a sensor foridentifying a registration feature on the continuous stock material; anda positioner, responsive to said sensor, for positioning said forge suchthat the forged portion of the continuous stock material islongitudinally spaced from the registration feature by a predetermineddistance, wherein said plurality of indexers comprise: an upstreamindexer for intermittently pushing the continuous stock material in thedownstream direction, said upstream indexer disposed upstream of saidforge; and a downstream indexer for intermittently pulling thecontinuous stock material in the downstream direction, said downstreamindexer disposed downstream of said forge, wherein said upstream anddownstream indexers are synchronized to longitudinally advance thecontinuous stock material in the downstream direction along thepredetermined path.
 28. An apparatus for forging a plurality of partsfrom a continuous stock material, wherein the continuous stock materialincludes a plurality of longitudinally spaced apart registrationfeatures, wherein the forging apparatus comprises: a plurality ofindexers which are synchronized to intermittently advance the continuousstock material along a predetermined path such that the stock materialadvances longitudinally in a downstream direction through the forgingapparatus; a forge which forges a portion of the continuous stockmaterial into a first predetermined shape following at least oneintermittent advancement of the continuous stock material; and atrimming station, downstream of said forge, for trimming predeterminedportions of each part, and wherein said trimming station comprises: atrimmer for trimming predetermined portions of each part; a sensor foridentifying a registration feature on the continuous stock material; anda positioner, responsive to said sensor, for positioning said trimmersuch that the predetermined portions which are trimmed arelongitudinally spaced from the registration feature by a predetermineddistance, wherein said plurality of indexers comprise: an upstreamindexer for intermittently pushing the continuous stock material in thedownstream direction, said upstream indexer disposed upstream of saidforge; and a downstream indexer for intermittently pulling thecontinuous stock material in the downstream direction, said downstreamindexer disposed downstream of said forge, wherein said upstream anddownstream indexers are synchronized to longitudinally advance thecontinuous stock material in the downstream direction along thepredetermined path.
 29. An apparatus for forging a plurality of partsfrom a continuous stock material, the apparatus comprising: a pluralityof indexers which are synchronized to intermittently advance thecontinuous stock material along a predetermined path such that the stockmaterial advances longitudinally in a downstream direction through theforging apparatus; a forge which forges a portion of the continuousstock material into a first predetermined shape following at least oneintermittent advancement of the continuous stock material; and means,upstream of said forge, for forming a registration feature in apredetermined portion of each parts, wherein said plurality of indexerscomprise: an upstream indexer for intermittently pushing the continuousstock material in the downstream direction, said upstream indexerdisposed upstream of said forge; and a downstream indexer forintermittently pulling the continuous stock material in the downstreamdirection, said downstream indexer disposed downstream of said forge,wherein said upstream and downstream indexers are synchronized tolongitudinally advance the continuous stock material in the downstreamdirection along the predetermined path.
 30. An apparatus according forforging a plurality of parts from a continuous stock material, whereinthe continuous stock material includes a plurality of longitudinallyspaced apart registration features, and wherein the forging apparatuscomprises: a plurality of indexers which are synchronized tointermittently advance the continuous stock material along apredetermined path such that the stock material advances longitudinallyin a downstream direction through the forging apparatus; a forge whichforges a portion of the continuous stock material into a firstpredetermined shape following at least one intermittent advancement ofthe continuous stock material; and a saw station, downstream of saidforge, for cutting each part from the continuous stock material tothereby separate the continuous stock material into a plurality ofdiscrete parts, and wherein said saw station comprises: a cutter forcutting each part from the continuous stock material; a sensor foridentifying a registration feature on the continuous stock material; anda positioner, responsive to said sensor, for positioning said cuttersuch that the portion of the continuous stock material which is cut islongitudinally spaced from the registration feature by a predetermineddistance, wherein said plurality of indexers comprise: an upstreamindexer for intermittently pushing the continuous stock material in thedownstream direction, said upstream indexer disposed upstream of saidforge; and a downstream indexer for intermittently pulling thecontinuous stock material in the downstream direction, said downstreamindexer disposed downstream of said forge, wherein said upstream anddownstream indexers are synchronized to longitudinally advance thecontinuous stock material in the downstream direction along thepredetermined path.
 31. A method of controlling a process for forming aplurality of parts from a continuous stock material, the methodcomprising: directing that the continuous stock material beintermittently advanced along a predetermined path such that the stockmaterial advances longitudinally in a downstream direction; directingthat a fixed portion of the continuous stock material be clampedfollowing at least one of the intermittent advancements of thecontinuous stock material so as to securely hold the fixed portion ofthe continuous stock material; directing that a portion of thecontinuous stock material be formed into a first predetermined shapewhile the fixed portion of the continuous stock material is clamped,wherein the fixed portion of the continuous stock material is disposedin a predetermined longitudinal direction from the formed portion of thecontinuous stock material, and wherein formation of the continuous stockmaterial in the fixed predetermined shape causes longitudinal growth ofthe continuous stock material; and directing that the longitudinalgrowth of the continuous stock material caused by the formation of thecontinuous stock material into the first predetermined shape be allowedto move in a longitudinal direction away from the formed portion of thecontinuous stock material and opposite the predetermined longitudinaldirection so as to at least partially compensate for the longitudinalgrowth of the continuous stock material.
 32. A method according to claim31 wherein directing that a portion of the continuous stock material beformed into the first predetermined shape comprises directing that aplurality of dies be at least partially closed about the continuousstock material, wherein the plurality of closed dies define a cavity ofa predetermined shape which defines the shape of at least a portion ofthe resulting part, and wherein the plurality of at least partiallyclosed dies define entry and exit ports through which the continuousstock material extends.
 33. A method according to claim 32 wherein theplurality of dies are mounted on a carriage which is adapted to movelongitudinally such that the longitudinal growth of the continuous stockmaterial between the formed portion of the continuous stock material andthe fixed portion of the continuous stock material causes the carriageto move in a longitudinal direction opposite the predeterminedlongitudinal direction in order to at least partially compensate for thelongitudinal growth of the continuous stock material, and wherein themethod further comprises directing that the carriage on which theplurality of dies are mounted be longitudinally biased with apredetermined longitudinal bias force so as to retard longitudinalmovement of the carriage.
 34. A method according to claim 32 furthercomprising: directing that the plurality of dies be opened after forminga portion of the stock material; directing that the clamped portion ofthe stock material be released such that the continuous stock materialcan be advanced along the predetermined path; and repeating the methodto form at least a portion of another part.
 35. A method according toclaim 31 further comprising: monitoring the longitudinal growth of thecontinuous stock material; and directing that the formation of theportion of the continuous stock material be halted once the longitudinalgrowth of the continuous stock material is at least as great as apredetermined longitudinal growth threshold.